TM2075 - Tecnico Operacion y Prueba 644J-724J

644J and 724J
Loader
Operation and Tests
TECHNICAL MANUAL
644J and 724J Loader Operation
and Tests
TM2075 03MAR05 (ENGLISH)
For complete service information also see:

644J and 724J Loader Repair . . . . . . . . . . . . TM2076
Alternators and Starting Motors . . . . . . . . . . CTM77
POWERTECH® 8.1 L Diesel Engines Base
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM86
TeamMate™ III 1000, 1200, and 1400 Series
Inboard Planetary Axles . . . . . . . . . . . . . . . . CTM150
POWERTECH® 8.1 L Diesel Engines Level 9
Electronic Fuel System with Denso
HPCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM255
120 Series Hydraulic Cylinders . . . . . . . . . . TM-H120A
185 Series Hydraulic Cylinders . . . . . . . . . . TM-H185A
SERVICE ADVISOR™ System Computer
Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . T133991
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician.

Essential tools required in performing certain service work
are identified in this manual and are recommended for
use.
Live with safety: Read the safety messages in the

introduction of this manual and the cautions presented
throughout the text of the manual.
This is the safety-alert symbol. When you see this

symbol on the machine or in this manual, be alert to the
potential for personal injury.
Technical manuals are divided in two parts: repair and

operation and tests. Repair sections tell how to repair the
components. Operation and tests sections help you
identify the majority of routine failures quickly.
Information is organized in groups for the various

components requiring service instruction. At the beginning
of each group are summary listings of all applicable
essential tools, service equipment and tools, other
materials needed to do the job, service parts kits,
specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific

machines. They are on-the-job guides containing only the
vital information needed for diagnosis, analysis, testing,
and repair.
Fundamental service information is available from other

sources covering basic theory of operation, fundamentals
of troubleshooting, general maintenance, and basic type
of failures and their causes.
TX,INTR,DU2141 –19–22MAR97–1/1
TM2075 (03MAR05) 644J and 724J Loader

092005
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Introduction
Technical Information Feedback Form
We need your help to continually improve our technical

publications. Please copy this page and FAX or mail your
comments, ideas and improvements.
SEND TO: John Deere Dubuque Works

P.O. Box 538
Attn: Publications Supervisor, Dept. 303
Dubuque, IA 52004-0538
FAX NUMBER: 563-589-5800
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THANK YOU!
TX,TM,FAX –19–03JUL01–1/1

092005
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Introduction

092005
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Contents
9000
SECTION 9000—General Information
Group 01—Safety Information
SECTION 9005—Operational Checkout Procedure

Group 10—Operational Checkout Procedure
9005
SECTION 9010—Engine
Group 05—Theory Of Operation
Group 15—Diagnostic Information
Group 25—Tests
9010
SECTION 9015A—Electrical System—724J (S.N. —
590067)
Group 05—System Information
Group 10—System Diagrams
Group 15—Sub-System Diagnostics
9015A
Group 20—References
SECTION 9015B—Electrical System—644J And

724J (S.N. 590068— )
Group 05—System Information
Group 10—System Diagrams 9015B
Group 15—Sub-System Diagnostics
Group 20—References
SECTION 9020—Power Train

9020
Group 20—Adjustments
Group 25—Tests
SECTION 9025—Hydraulic System

Group 05—Theory Of Operation 9025
Group 25—Test
SECTION 9031—Heating And A/C

9031
Group 25—Tests
INDX
All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT © 2004
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION® Manual
Previous Editions
Copyright © 2002, 2003
TM2075 (03MAR05) i 644J and 724J Loader

092005
PN=1
Contents
9000
9005
9010
9015A
9015B
9020
9025
9031
INDX
TM2075 (03MAR05) ii 644J and 724J Loader

092005
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9000
Section 9000
General Information
Contents
Page
Group 01—Safety Information

Recognize Safety Information . . . . . . . . . . . .9000-01-1
Follow Safety Instructions . . . . . . . . . . . . . . .9000-01-1
Operate Only If Qualified. . . . . . . . . . . . . . . .9000-01-2
Wear Protective Equipment . . . . . . . . . . . . . .9000-01-2
Avoid Unauthorized Machine
Modifications . . . . . . . . . . . . . . . . . . . . . . .9000-01-2
Add Cab Guarding For Special Uses . . . . . .9000-01-3
Inspect Machine . . . . . . . . . . . . . . . . . . . . . .9000-01-3
Stay Clear Of Moving Parts. . . . . . . . . . . . . .9000-01-3
Avoid High-Pressure Fluids . . . . . . . . . . . . . .9000-01-4
Beware Of Exhaust Fumes . . . . . . . . . . . . . .9000-01-4
Prevent Fires. . . . . . . . . . . . . . . . . . . . . . . . .9000-01-5
Prevent Battery Explosions . . . . . . . . . . . . . .9000-01-5
Handle Chemical Products Safely . . . . . . . . .9000-01-6
Dispose of Waste Properly . . . . . . . . . . . . . .9000-01-6
Prepare for Emergencies. . . . . . . . . . . . . . . .9000-01-6
Use Steps And Handholds Correctly . . . . . . .9000-01-7
Start Only From Operator’s Seat . . . . . . . . . .9000-01-7
Use And Maintain Seat Belt . . . . . . . . . . . . .9000-01-7
Prevent Unintended Machine Movement . . . .9000-01-8
Avoid Work Site Hazards . . . . . . . . . . . . . . .9000-01-8
Use Special Care When Operating
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-9
Keep Riders Off Machine . . . . . . . . . . . . . . .9000-01-9
Avoid Backover Accidents . . . . . . . . . . . . . .9000-01-10
Avoid Machine Tip Over . . . . . . . . . . . . . . .9000-01-10
Operating on Slopes . . . . . . . . . . . . . . . . . .9000-01-11
Operating Or Traveling On Public Roads . .9000-01-11
Inspect and Maintain ROPS . . . . . . . . . . . .9000-01-12
Add And Operate Attachments Safely . . . . .9000-01-12
Park And Prepare For Service Safely . . . . .9000-01-13
Service Cooling System Safely . . . . . . . . . .9000-01-13
Remove Paint Before Welding or
Heating . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-14
Make Welding Repairs Safely . . . . . . . . . . .9000-01-14
Drive Metal Pins Safely . . . . . . . . . . . . . . . .9000-01-15
TM2075 (03MAR05) 9000-1 644J and 724J Loader

092005
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Contents
9000

092005
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Group 01
Safety Information
9000
Recognize Safety Information 01
1
This is the safety alert symbol. When you see this
–UN–28AUG00
symbol on your machine or in this manual, be alert
for the potential of personal injury.
Follow the precautions and safe operating practices
T133555
highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is

used with the safety alert symbol. DANGER identifies the
most serious hazards.
–19–28AUG00
On your machine, DANGER signs are red in color,
WARNING signs are orange, and CAUTION signs are
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
T133588
labels.
TX03679,00016CC –19–21AUG00–1/1
Follow Safety Instructions
Read the safety messages in this manual and on the
–UN–24AUG00
machine. Follow these warnings and instructions carefully.
Review them frequently. Keep safety signs in good
condition. Replace missing or damaged safety signs.
Replacement safety signs are available from your John
T133556
Deere dealer.
Be sure all operators of this machine understand every

safety message. Replace operator’s manual and safety
labels immediately if missing or damaged.
TX03679,00016F9 –19–13OCT03–1/1
TM2075 (03MAR05) 9000-01-1 644J and 724J Loader

092005
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Safety Information
9000
01 Operate Only If Qualified
2
Do not operate this machine unless you have read the machine functions with the machine in an open area
operator’s manual carefully and you have been before starting to work.
qualified by supervised training and instruction.
Know and observe all safety rules that may apply to
Familiarize yourself with the job site and your your work situation and your work site.
surroundings before operating. Try all controls and
TX03679,00016FA –19–30OCT00–1/1
Wear Protective Equipment
Guard against injury from flying pieces of metal or debris;

wear goggles or safety glasses.
Wear close fitting clothing and safety equipment

appropriate to the job.
–UN–23AUG88
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or
TS206
uncomfortable loud noises.
TX03679,00016D0 –19–30OCT00–1/1
Avoid Unauthorized Machine Modifications
Modifications of this machine, or addition of Always contact an authorized dealer before making
unapproved products or attachments, may affect machine modifications that change the intended use,
machine stability or reliability, and may create a hazard weight or balance of the machine, or that alter
for the operator or others near the machine. The machine controls, performance or reliability.
installer of any modification which may affect the
electronic controls of this machine is responsible for
establishing that the modification does not adversely
affect the machine or its performance.
TX03679,00016B7 –19–13OCT03–1/1

092005
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Safety Information
9000
Add Cab Guarding For Special Uses 01
3
Special work situations or machine attachments may

create an environment with falling or flying objects.
Loading logs, using fork attachments, or operating in
waste management applications requires special work
–UN–04MAY01
tools. Added cab guarding to protect the operator may
also be required.
Use load-clamping grapples to keep bulky loads from
T141893
falling and add special screens or guarding when objects
may be directed toward the cab. Contact your authorized
dealer for information on devices intended to protect the
operator from falling or flying objects in special work
situations.
TX03679,00017C6 –19–01JUN01–1/1
Inspect Machine
Inspect machine carefully each day by walking around it

before starting.
Keep all guards and shields in good condition and
–UN–18OCT88
properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.
T6607AQ
TX03679,0001734 –19–25SEP00–1/1
Stay Clear Of Moving Parts
–UN–12SEP01
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining

any part of machine with moving parts.
T133592
Keep guards and shields in place. Replace any guard or

shield that has been removed for access as soon as
service or repair is complete.
TX03679,00016D2 –19–30OCT00–1/1

092005
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Safety Information
9000
01 Avoid High-Pressure Fluids
4
This machine uses a high-pressure hydraulic system.

Escaping fluid under pressure can penetrate the skin
–UN–31OCT00
causing serious injury.
Never search for leaks with your hands. Protect hands.

Use a piece of cardboard to find location of escaping fluid.
T133509
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
If hydraulic fluid penetrates your skin, see a doctor

immediately. Injected fluid must be removed
surgically within hours or gangrene may result.
–UN–20SEP00
Contact a knowledgeable medical source or the Deere &
Company Medical Department in Moline, Illinois, U.S.A.
T133840
TX03679,00016D3 –19–30OCT00–1/1
Beware Of Exhaust Fumes
Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
–UN–24AUG00
If you must operate in a building, provide adequate
ventilation. Use an exhaust pipe extension to remove the
exhaust fumes or open doors and windows to bring
T133546
outside air into the area.
TX03679,00016D4 –19–14SEP00–1/1

092005
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Safety Information
9000
Prevent Fires 01
5
–UN–14SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
T133552
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines and electrical wiring. Never store
oily rags or flammable materials inside a machine
compartment.
–UN–07SEP00
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
T133553
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a

multi-purpose fire extinguisher on or near the machine.
–UN–07SEP00
Know how to use extinguisher properly.
T133554
TX03679,00016F5 –19–25SEP00–1/1
Prevent Battery Explosions
Battery gas can explode. Keep sparks, lighted matches,

and open flame away from the top of battery.
Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.
–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
TS204
TX03679,000174A –19–14SEP00–1/1

092005
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Safety Information
9000
01 Handle Chemical Products Safely
6
Exposure to hazardous chemicals can cause serious
–UN–25AUG00
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.
T133580
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.
TX03679,00016D7 –19–05AUG02–1/1
Dispose of Waste Properly
Improper disposal of waste can threaten the environment.
–UN–25AUG00
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
T133567
any water source.
Air conditioning refrigerants can damage the atmosphere.

Government regulations may require using a certified
service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your

local environmental or recycling center or your dealer for
more information.
TX03679,0001733 –19–14SEP00–1/1
Prepare for Emergencies
Be prepared if an emergency occurs or a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,

–UN–23AUG88
hospital, and fire department near your telephone.

TS291
TX03679,000174B –19–14SEP00–1/1

092005
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Safety Information
9000
Use Steps And Handholds Correctly 01
7
Prevent falls by facing the machine when you get on and
–UN–30AUG00
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present
T133468
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
TX03679,00016F2 –19–14SEP00–1/1
Start Only From Operator’s Seat
–UN–07SEP00
Avoid unexpected machine movement. Start engine only
while sitting in operator’s seat. Ensure all controls and
working tools are in proper position for a parked machine.
T133715
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.
TX03679,0001799 –19–02MAY01–1/1
Use And Maintain Seat Belt
Use seat belt when operating machine. Remember to
–19–14SEP00
fasten seat belt when loading and unloading from trucks
and during other uses.
T133716
Examine seat belt frequently. Be sure webbing is not cut
or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced

every three years, regardless of appearance.
TX03679,00016DD –19–17OCT00–1/1

092005
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Safety Information
9000
01 Prevent Unintended Machine Movement
8
When co-workers are present, disable hydraulics.
–UN–15MAY01
Lower all equipment to the ground during work
interruptions. Lock transmission control in neutral, engage
park brake and stop engine before allowing anyone to
approach the machine.
T142001
Follow these same precautions before standing up,
leaving the operator’s seat, or exiting the machine.
TX03679,00017C7 –19–28OCT02–1/1
Avoid Work Site Hazards
Avoid contact with gas lines, buried cables and water

lines. Call utility line location services to identify all
–UN–15JUN01
underground utilities before starting work.
Prepare work site properly. Avoid operating near

structures or objects that could fall onto the machine.
T141894
Clear away debris that could move unexpectedly if run
over.
Avoid boom or attachment contact with overhead

obstacles or overhead electrical lines. Never move any
part of machine or load closer than 3 m (10 ft) plus twice
the line insulator length to overhead wires.
–UN–24APR01
Keep bystanders clear at all times. Use barricades or a
signal person to keep vehicles and pedestrians away. Use
a signal person if moving machine in congested areas or T141670
where visibility is restricted. Always keep signal person in

view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient to

support machine. Be especially alert working near
embankments or excavations.
–UN–04MAY01
Avoid working under over-hanging embankments or

stockpiles that could collapse on machine.
T141672
TX03679,000179A –19–02MAY01–1/1

092005
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Safety Information
9000
Use Special Care When Operating Loader 01
9
Never use the loader to lift people. Do not allow

anyone to ride in the bucket or use the bucket as a
–UN–15MAY01
work platform.
Operate carefully with raised loads. Raising the load

reduces machine stability, especially on side slopes or an
T141957
unstable surface. Drive and turn slowly with a raised load.
Ensure that objects in the bucket are secure. Do not

attempt to lift or carry objects that are too big or too long
to fit inside the bucket unless secured with an adequate
chain or other device. Keep bystanders away from raised
loads.
–UN–07MAY01
Be careful when lifting objects. Never attempt to lift
objects too heavy for your machine. Assure machine
stability and hydraulic capability with a test lift before
T141902
attempting other maneuvers. Use an adequate chain or
sling and proper rigging techniques to attach and stabilize
loads. Never lift an object above or near another person.
TX03768,0000B70 –19–14MAY01–1/1
Keep Riders Off Machine
Only allow operator on machine.
–UN–04MAY01
Riders are subject to injury. They may fall from machine,
be caught between machine parts, or be struck by foreign
objects.
T141671
Riders may obstruct operator’s view or impair his ability to
operate machine safely.
TX03679,000179B –19–20APR01–1/1

092005
PN=17
Safety Information
9000
01 Avoid Backover Accidents
10
Before moving machine, be sure all persons are clear

of machine path. Turn around and look directly for best
–UN–04MAY01
visibility. Use mirrors to assist in checking all around
machine. Keep windows and mirrors clean, adjusted, and
in good repair.
T141673
Be certain reverse warning alarm is working properly.
Use a signal person when backing if view is

obstructed or when in close quarters. Keep signal
person in view at all times. Use prearranged hand signals
to communicate.
TX03679,000179C –19–20APR01–1/1
Avoid Machine Tip Over
Use seat belt at all times.
–19–14SEP00
Do not jump if the machine tips. You will be unlikely to
jump clear and the machine may crush you.
T133716
Load and unload from trucks or trailers carefully. Be
sure truck is wide enough and on a firm level surface. Use
loading ramps and attach them properly to truck bed.
Be careful on slopes. Avoid sharp turns. Balance loads

so weight is evenly distributed and load is stable. Carry
tools and loads close to the ground to aid visibility and
lower center of gravity. Use extra care on soft, rocky or
–UN–04MAY01
frozen ground.
Know the capacity of the machine. Do not overload. Be

careful with heavy loads. Using oversize buckets or lifting T141676
heavy objects reduces machine stability.
Ensure solid footing. Use extra care in soft ground

conditions that may not uniformly support the wheels,
especially when raising the boom. Do not operate close to
banks or open excavations that may cave in and cause
machine to tip or fall.
–UN–04MAY01
T141672
TX03679,000179D –19–02MAY01–1/1

092005
PN=18
Safety Information
9000
Operating on Slopes 01
11
Avoid side slope travel whenever possible. Drive up steep

slope in forward and down in reverse.
–UN–30APR01
Select low gear speed before starting down slope. The
grade of the slope will be limited by ground condition and
load being handled.
T141681
Use service brakes to control speed. Sudden brake
application with a loaded bucket on downhill side could
cause machine to tip forward.
TX03679,000179E –19–14MAY01–1/1
Operating Or Traveling On Public Roads
Machines that work near vehicle traffic or travel slower

than normal highway speeds must have proper lighting
–UN–22MAY01
and markings to assure they are visible to other drivers.
Install additional lights, beacons, slow moving vehicle

(SMV) emblems, or other devices and use as required to
T141891
make the machine visible and identify it as a work
machine. Check state and local regulations to assure
compliance. Keep these devices clean and in working
condition.
TX03679,00017C8 –19–14JUN01–1/1

092005
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Safety Information
9000
01 Inspect and Maintain ROPS
12
A damaged roll-over protective structure (ROPS) To maintain the ROPS:

should be replaced, not reused.
• Replace missing hardware using correct grade
The protection offered by ROPS will be impaired if hardware.
ROPS is subjected to structural damage, is involved in • Check hardware torque.
an overturn incident, or is in any way altered by • Check isolation mounts for damage, looseness or
welding, bending, drilling, or cutting. wear; replace them if necessary.
• Check ROPS for cracks or physical damage.
If ROPS was loosened or removed for any reason,
inspect it carefully before operating the machine again.
TX03679,000179F –19–20APR01–1/1
Add And Operate Attachments Safely
Always verify compatibility of attachments by that all connections are secure and attachment
contacting your authorized dealer. Adding unapproved responds properly to controls.
attachments may affect machine stability or reliability,
and may create a hazard for others near the machine. Carefully read attachment manual and follow all
instructions and warnings. In an area free of
Ensure that a qualified person is involved in bystanders and obstructions, carefully operate
attachment installation. Add guards to machine if attachment to learn its characteristics and range of
operator protection is required or recommended. Verify motion.
TX03679,00016F0 –19–14SEP00–1/1

092005
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Safety Information
9000
Park And Prepare For Service Safely 01
13
Warn others of service work. Always park and prepare

your machine for service or repair properly.
• Park machine on a level surface and lower equipment
–19–14DEC01
to the ground.
• Engage park brake.
• Stop engine and remove key.
• Install articulation locking bar.
T133332
• Attach a “Do Not Operate” tag in an obvious place in
the operator’s station.
Securely support machine or attachment before working

under it.
• Do not support machine with boom, bucket, or other

hydraulically actuated equipment.
• Do not support machine with cinder blocks or wooden
pieces that may crumble or crush.
–UN–23AUG88
• Do not support machine with a single jack or other
devices that may slip out of place.
Understand service procedures before beginning repairs.
TS229
Keep service area clean and dry. Use two people
whenever the engine must be running for service work.
TX03679,00017A0 –19–18SEP01–1/1
Service Cooling System Safely
Explosive release of fluids from pressurized cooling

system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
–UN–23AUG88
to relieve pressure before removing completely.

TS281
DX,RCAP –19–04JUN90–1/1

092005
PN=21
Safety Information
9000
01 Remove Paint Before Welding or Heating
14
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
–UN–23AUG88
Remove paint before heating:
• Remove paint a minimum of 101 mm (4 in.) from area

to be affected by heating. If paint cannot be removed,
TS220
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do not use a chlorinated solvent in areas where welding

will take place.
Do all work in an area that is well ventilated to carry toxic

fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT –19–24JUL02–1/1
Make Welding Repairs Safely
NOTE: Disable electrical power before welding. Turn off

–UN–31AUG00
main battery switch or disconnect positive battery
cable. Separate harness connectors to engine and
vehicle microprocessors.
T133547
Avoid welding or heating near pressurized fluid lines.

Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes.

Use a qualified welding technician for structural repairs.
Make sure there is good ventilation. Wear eye protection
and protective equipment when welding.
TX03679,00016D5 –19–02OCT00–1/1

092005
PN=22
Safety Information
9000
Drive Metal Pins Safely 01
15
–UN–14SEP00
Always wear protective goggles or safety glasses and
other protective equipment before striking hardened parts.
Hammering hardened metal parts such as pins and
bucket teeth may dislodge chips at high velocity.
T133738
Use a soft hammer or a brass bar between hammer and
object to prevent chipping.
TX03679,0001745 –19–25SEP00–1/1

092005
PN=23
Safety Information
9000
01
16

092005
PN=24
Section 9005
Operational Checkout Procedure
Contents 9005
Page
Group 10—Operational Checkout Procedure

Complete Machine Operational Checkout . . .9005-10-1
Engine Off Checks . . . . . . . . . . . . . . . . . . . .9005-10-1
Engine Running Checks . . . . . . . . . . . . . . . .9005-10-5

092005
PN=1
Contents
9005

092005
PN=2
Group 10
Complete Machine Operational Checkout
Use this procedure to make a quick check of machine

operation by doing a walk around inspection and
performing specific checks from operator’s seat.
9005
10
Complete visual checks (oil levels, oil condition, external 1
leaks, loose hardware, linkage, wiring, etc.) before
performing checkout.
Most checks will require machine systems to be at normal

operating temperatures and a level area with adequate
space to operate machine. Some checks may require
varied surfaces.
No special tools are necessary to perform the checkout.
If no problem is found, go to next check. If problem is

indicated, an additional check or repair procedure will be
suggested.
MF82180,000016D –19–13NOV03–1/1
1 Engine Off Checks
– – –1/1
Battery Check (S.N. — Key OFF. YES: Go to next check.

590067)
Press SELECT button and hold until battery volts are NO: See Monitor Display
displayed. Unit—Diagnostics Menu
(S.N. —590067). (Group
LOOK: Does battery volts read a minimum of 24 volts? 9015A-15.) Check voltage
on each battery before
recharging.
T103154 –UN–10SEP96
If one battery will not hold
a charge, replace both
batteries.
– – –1/1

092005
PN=27
Battery Check (S.N. Key OFF. YES: Go to next check.

590068— )
65.1 Press SELECT button and hold until battery volts are
displayed.
NO: See CAN Monitor
Unit (CMU) Circuit Theory
9005
25.0 LOOK: Does battery volts read a minimum of 24 volts?
of Operation (S.N.
590068— ). (Group
9015B-15.) Check voltage
10
on each battery before
2
T194308 –UN–11SEP03 recharging.
If one battery will not hold

a charge, replace both
batteries.
– – –1/1
Monitor Check (S.N. — Key switch on. YES: Go to next check.

590067)
Observe monitor and note changes for first 3 seconds (bulbs, indicators and gauges). NO: Check Monitor
Switched Power fuse.
LOOK/LISTEN: Do all lights come on and does alarm sound? See Fuse And Relay
Specifications (S.N. —
Does message display and basic display window have “8s” showing in every display? 590067). (Group
9015A-10.)
Do all the gauge indicators point to approximately 12:00 o’clock position?
Is backlighting of gauges on?
After 4 seconds observe changes in Monitor.
LOOK: Do gauge indicators change from 12:00 o’clock to normal readings?
Does Message Display show John Deere?
LOOK: Does Basic Display change to show gear, rpm, hourmeter and battery voltage
readings?
– – –1/1
Monitor Check (S.N. Key switch on. YES: Go to next check.

590068— )
Observe Monitor and note changes for first 3 seconds (Bulbs, Indicators and Gauges). NO: Check CMU/SSM
ignition power 5 A fuse.
LOOK/LISTEN: Do all lights come on and does alarm sound? See Fuse and Relay
Specifications (S.N.
Does the LCD display show John Deere and the model number? 590068— ). (Group
9015B-10.)
Do all the gauge indicators point to approximately 12:00 O’ clock position?
After 4 seconds observe changes in Monitor.
LOOK: Do gauge indicators change from 12:00 O’clock to normal readings?
Does the LCD show gear, engine speed, and hourmeter/speedometer/odometer?
– – –1/1

092005
PN=28
Cab System Checks Check the following for proper working order: YES: Go to next check.
• Seat Adjustment NO: Go to specific circuit.

• Seat Belt See System Functional
• Tilt Wheel Counsel Schematic (S.N. —
• Dome light 590067). (Group
9005
• Horn 9015A-10.) See System
10
• Front and rear windshield wiper and washer Functional Schematic and
3
• Four speed (five position) blower fan Schematic Legend (S.N.
• Door and window latches 590068— ). (Group
• Front and rear work lights 9015B-10.)
• Front and rear drive lights
• Turn signals
• Side shield latches
• Grill housing door latch
• Radiator cap and Fuel door checks
• Cab Mount Ladder
• Boom Lock check
• Service Decal check
– – –1/1
Transmission Control Push automatic transmission switch to OFF position. YES: Go to next check.
Lever And Neutral Lock
Latch Checks Move transmission control lever to Forward (F), Neutral and Reverse (R) positions. NO: If lever does not
move or lock properly,
LOOK: Does lever move into Forward, Neutral and Reverse positions easily? replace lever.
Does lever stay in detented positions? NO: If gears do not

change on monitor, check
Does back-up alarm sound? control lever circuit. See
Front Console Harness
Put neutral lock in LOCKED position. Component Location
(S.N. —590067) for
Apply slight effort to move lever into forward (F) and reverse (R). connector specifications.
(Group 9015A-10.) See
LOOK: Does neutral lock stay engaged and lever stay in neutral? Transmission Control Unit
(TCU) Circuit Theory of
Put neutral lock in UNLOCK position. Operation (S.N. 590068—
). (Group 9015B-15.)
Twist lever to shift into each gear 1st, 2nd, 3rd and 4th.
LOOK: Does gear number align with pointer in each detented position?
Does twist handle remain in detented positions?
Does Basic Display indicate correct gear and “N” position? (1 N, 2 N, 3 N and 4 N)
– – –1/1

092005
PN=29
Neutral Start Check Move transmission control lever to 1st gear forward (1F), turn key switch to START. YES: Go to next check.
(S.N. —590067)
LISTEN: Starting motor must not run. NO: Check Neutral Start
Circuit Relay (K1), See
NOTE: Gear display will not display “F” for forward or “R” for reverse until engine is Fuse And Relay
started and park brake released. Specifications (S.N. —
9005
590067). (Group
10
Move transmission control lever to 1st gear reverse (1R), turn key switch to START. 9015A-10.)
4
LISTEN: Starting motor must not run. Back-up alarm will sound. IF OK: See Start Circuit
(S.N. —590067). (Group
With transmission control lever in neutral (1N), turn key switch to START. 9015A-15.)
LISTEN: Does starting motor run with lever in neutral position only?
– – –1/1
Neutral Start Check (S.N. Move transmission control lever to 1st gear forward (1F) of to 1st gear reverse (1R), YES: Go to next check.
590068— ) turn key switch to START.
NO: See Starting and
LOOK/LISTEN: Does engine start? Charging Circuit Theory
of Operation (S.N.
Does LCD display indicate a neutral gear selection? 590068— ). (Group
9015B-15.)
NOTE: Gear display will not display “F” for forward or “R” for reverse until shifter is
cycled back to neutral and park brake released.
– – –1/1
Diagnostic Trouble Check Diagnostic Trouble Codes (DTC). Diagnostic Trouble Codes can be displayed IF OK: Continue on with
Codes (DTC) (S.N. — using SERVICE ADVISOR™ system or monitor on machine. check.
590067)
Display diagnostic trouble codes using SERVICE ADVISOR system:
1. Establish a live connection to machine. See Service ADVISOR System Computer

Connection for information on connecting to J-Series loaders (S.N. —590067).
2. Select Diagnostic Trouble Codes icon under Readings tab.
Display diagnostic trouble codes using machine monitor:
See Monitor Display Unit—Diagnostics Menu (S.N. —590067), Diagnostic Trouble

Code (DTC) (d 01). (Group 9015A-15.)
Record which (DTC) appears.
Clear (DTC).
If any (DTC) remains, fix before continuing with checks. See Diagnostic Trouble Codes
Quick Reference (S.N. —590067). (Group 9015A-20.)
SERVICE ADVISOR is a trademark of Deere & Company – – –1/1

092005
PN=30
Diagnostic Trouble Check Diagnostic Trouble Codes (DTC). Diagnostic Trouble Codes can be displayed IF OK: Continue on with
Codes (DTCs) (S.N. using SERVICE ADVISOR™ system or monitor on machine. check.
590068— )

9005
Connection for information on connecting to J-Series loaders (S.N. 590068—).
10
5
View codes on the Active Codes screen and Stored Codes screen. Press NEXT to
scroll through the codes if more than one exists. See CAN Monitor Unit (CMU) Circuit
Theory of Operation (S.N. 590068— ). (9015B-15.)
Record any DTCs that appears.
Press and hold the MENU button on the CAN Monitor Unit (CMU) for 5 seconds to
enter the service menu.
Press SELECT to enter the codes menu.
Press NEXT until Clear Codes is highlighted and press SELECT.
Press SELECT to clear DTCs.
If any DTCs remain, fix before continuing with checks. See Diagnostic Trouble Codes
Quick Reference List (S.N. 590068— ). (Group 9015B-20.)
2 Engine Running Checks
– – –1/1
Monitor Check (S.N. — Start Engine. YES: Go to next check.

590067)
Observe Monitor and check bulbs, indicators and gauges. NO: Check Monitor
Switched Power Fuse
LOOK/LISTEN: Do all lights come on. (F7). See Fuse And
Relay Specifications
Does alarm sound? (S.N. —590067). (Group
9015A-10.)
IF OK: See Monitor
After 4 seconds observe changes in Monitor. Display Unit—Diagnostics
Menu (S.N. —590067).
LOOK: Do gauges show normal readings? (Group 9015A-15.)
Does Basic Display change to show gear, rpm, hourmeter and battery voltage
readings?
Is battery volts reading 24—27.6?
Does engine speed read idle speed?
On monitor does seat belt indicator go OFF 5 seconds after engine starts?
– – –1/1

092005
PN=31
Monitor Check (S.N. Start Engine. YES: Go to next check.

590068— )
Observe CMU and check bulbs, indicators and gauges. NO: Check CMU/SSM
ignition power 5 A fuse
LOOK/LISTEN: Do all lights illuminate? (F13). See Fuse and
Relay Specifications (S.N.
9005
Does monitor alarm sound? 590068— ). (Group
10
9015B-10.)
6
IF OK: Check appropriate
After 4 seconds observe changes in Monitor. diagnostic item on
diagnostics menu. See
LOOK: Do gauges show normal readings? CAN Monitor Unit (CMU)
Circuit Theory of
Does home screen change to show gear, rpm, and hourmeter/speedometer/odometer? Operation (S.N. 590068—
). (Group 9015B-15.)
Does engine speed read idle speed?
Does seat belt indicator go OFF 5 seconds after engine starts?
– – –1/1
Diagnostic Trouble Check Diagnostic Trouble Codes (DTC). Diagnostic Trouble Codes can be displayed IF OK: Go to next check.
Codes (DTC) (S.N. — using SERVICE ADVISOR™ system or monitor on machine.
590067)

Connection for information on connecting to J-Series loaders (S.N. —590067).
See Monitor Display Unit—Diagnostics Menu (S.N. —590067), Diagnostic Trouble

Code (DTC) (d 01). (Group 9015A-15.)
Record which (DTC) appears.
Clear (DTC).
If any (DTC) remains, fix before continuing with checks. See Diagnostic Trouble Codes
Quick Reference (S.N. —590067). (Group 9015A-20.)

092005
PN=32
Diagnostic Trouble Check Diagnostic Trouble Codes (DTC). Diagnostic Trouble Codes can be displayed IF OK: Go to next check.
Codes (DTCs) (S.N. using SERVICE ADVISOR™ system or monitor on machine.
590068— )

9005
Connection for information on connecting to J-Series loaders (S.N. 590068— ).
10
7
View codes on the Active Codes screen and Stored Codes screen. Press NEXT to
scroll through the codes if more than one exists. See CAN Monitor Unit (CMU) Circuit
Theory of Operation (S.N. 590068— ). (Group 9015B-15.)
Record any DTCs that appears.
Press and hold the MENU button on the CAN Monitor Unit (CMU) for 5 seconds to
enter the service menu.
Press SELECT to enter the codes menu.
Press NEXT until Clear Codes is highlighted and press SELECT.
Press SELECT to clear DTCs.
If any DTCs remain, fix before continuing with checks. see Diagnostic Trouble Codes
Quick Reference List (S.N. 590068— ). (Group 9015B-20.)
Hydraulic and IMPORTANT: For the following checks all systems must be warmed up to YES: Go to next check.
Transmission Oil-Warm operating range to get accurate test results (50—65 °C (120—150 °F ).
Up Procedure
See Hydraulic Oil Warm-Up Procedure.
See Transmission Oil Warm-Up Procedure.

– – –1/1
Park Brake Check Release park brake by pushing park brake switch to YES: Go to next check.
OFF position. See Park Brake Switch for switch
operation. (Operators Manual.) NO: See Park Brake
Circuit Theory Of
LOOK: Does park brake indicator go off when brake is Operation (S.N. —
released? Will machine move if put into gear? 590067). (Group
9015A-15.)
T103441 –UN–09SEP96
CAUTION: Seat belt must be worn during this See Transmission Control
check to prevent possible injury from sudden Unit (TCU) Circuit Theory
machine stops. of Operation (S.N.
590068— ). (Group
Fasten seat belt. 9015B-15.)
Put transmission in 1st gear forward. NO: If machine does not

stop within specified
Drive machine at 3 MPH and push park brake switch to distance, See Repair
on. Park Brake. (Group
1160.)
LOOK/FEEL: Does machine come to a stop within 1
meter (3 feet) when park brake is engaged at 3 MPH?
Does transmission shift to neutral?
– – –1/1

092005
PN=33
Service Brake Check Move each pedal with hand to check “free travel.” YES: Go to next check.
FEEL: Does each pedal have about 6 mm (0.25 in.) free travel? NO: Inspect for debris
under brake pedal.
Inspect brake pedal
linkage for damage.
9005
10
8 Disable clutch cut-off. YES: Go to next check.
Fully apply either service brake pedal. NO: See Inspect External
Service Brakes. (Repair
Push park brake switch to OFF. Manual, Group 1011.)
Put transmission in 2nd forward. IF OK: Inspect for leaks

from brake system Go to
Increase engine speed to high idle. Diagnose Service Brake
Malfunctions. (Group
LOOK: Does machine remain stationary or move very slowly? 9020-15.)
Repeat check three times to ensure accurate results.
– – –1/1
Clutch Cut-Off Check Turn Clutch Cut-Off Switch (NEUTRAL) on. YES: Go to next check.
(S.N. —590067)
Apply brake. NO: Check Clutch Cut-Off
Switch.
Increase engine rpm to 1500.
IF OK: Check Clutch
Turn NEUTRAL switch off. Cut-Off Sensor using
monitor.See Monitor
LISTEN/LOOK: Does engine rpm drop? Display Unit—Diagnostics
Menu (S.N. —590067)
FEEL: Can you feel machine pull through brakes? Transmission Sensor
(D05). (Group 9015A-15.)
NOTE: Clutch cut-off switch can be adjusted to operator preference to match your
loading needs by selecting one of three operating functions in the monitor. See Clutch Cut-Off
Transmission does not totally disengage, some effort to move by the machine can be Sensor Check and
felt. See Monitor Display Unit—Accessory Menu (S.N. —590067) Clutch cut-off (A01). Adjustment (S.N. —
(Group 9015A-15.) 590067). (Group
9015A-20.)
– – –1/1

092005
PN=34
Clutch Cut-Off Check Press Clutch Cut-Off Switch to enable clutch cut-off at YES: Go to next check.
(S.N. 590068— ) any slope. LEDs will illuminate.
NO: Check clutch cut-off
Apply brake. sensor
Increase engine rpm to 1500. IF OK: Check Clutch

9005
Cut-Off Sensor using
10
Press clutch cut-off switch until clutch cut-off is turned CAN Monitor Unit (CMU).
9
T194311 –UN–11SEP03 off. All LEDs will be off. See CAN Monitor Unit
(CMU) Circuit Theory of
LISTEN/LOOK: Does engine rpm drop? Operation (S.N. 590068—
), Diagnostics menu,
FEEL: Can you feel machine pull through brakes? Transmission Sensors
menu. (Group 9015B-15.)
See Clutch Cut-Off

Sensor Adjustment (S.N.
590068— ). (Group
9015B-20.)
– – –1/1
Automatic Shift And NOTE: In the AUTOMATIC mode, transmission will shift to highest gear selected as YES: Go to next check.
Speedometer Check ground speed increases, or will down shift to 2nd as ground speed decreases.
Transmission will never shift to 1st gear. In AUTO MODE TO FIRST the transmission NO: Monitor is
will start in 1st when initially shifted from Neutral to Forward or Reverse. After the initial programmed for wrong
shift from Neutral, the transmission will downshift no lower than 2nd unless a high load tire size. See Monitor
is encountered. Transmission will upshift or downshift as ground speed dictates. Display Unit—Service
Menu (S.N. —590067),
Automatic transmission switch to AUTO. Tire size (S03). (Group
9015A-15.)
Perform this check in an open area away from other people and machinery.
CMU is programmed for
Release park brake and shift to (4th) forward. wrong tire size. Enter
service menu in CMU,
Drive machine on level ground and slowly accelerate to fast idle speed and note speed choose Machine Config,
when shifts are made until engaged in 4th gear. Reduce engine rpm to idle and note then Tire Size. See CAN
speed when transmission makes each downshift. Monitor Unit (CMU)
Circuit Theory of
LOOK: Does the transmission shift at following approximate speeds? Operation (S.N. 590068—
). (Group 9015B-15.)
644J, 724J
Shift MPH Km/H IF OK: Check
Transmission Output
2nd-3rd 6 9 Shaft Speed Sensor. If
3rd-4th 10 16 Sensor has failed,
speedometer will not work
4th-3rd 7 11
and transmission will not
3rd-2nd 4 6 shift above 2nd. See
Transmission Modes Of
NOTE: In 4th Forward automatic the transmission starts out in 2nd gear and up-shifts Operation—Manual And
to 3rd then 4th. When transmission downshifts it returns to 2nd. Transmission will shift Automatic (S.N. —
590067). (Group
at different speeds depending on machine loads. Use only as reference.
9015A-15.) See
Transmission Control Unit
(TCU) Circuit Theory of
Operation (S.N. 590068—
). (Group 9015B-15.)
– – –1/1

092005
PN=35
Transmission Shift Mode Turn Automatic Transmission Shift switch to OFF. YES: Go to next check.
Check (S.N. —590067)
Press MENU until ACCESSORY shows in basic display, then press SELECT. NO: Check Rocker,
Restriction, Radio
Accessory will display in Message Display Window and A 02 Quick Shift in Basic Switches Fuse (F23). See
Display Window. Transmission Control Unit
9005
Circuit (S.N. —590067).
10
Press NEXT until A 021 Down/up displays, then press SELECT. (Group 9015A-15.)
10
Release park brake and shift to 3rd forward. NO: Check Quick Shift
Switch. See Transmission
Drive machine at approximately 1600 rpm and press Quick Shift Switch once. Control Unit Circuit
(S.N. —590067). (Group
LOOK/FEEL: Does transmission shift to and remain in 2nd gear? 9015A-15.)
Press Quick Shift Switch once more.
LOOK/FEEL: Does transmission shift back to 3rd gear?
NOTE: If Quick Shift Switch is pressed twice, transmission will shift down one gear
then immediately back up to where it was. Quick Shift feature operates in all gears.
In Basic Display Window with Quick Shift A 021 displayed press NEXT to get
Downshift A 022 Down Only to display.
Press SELECT to enable Down Only shift mode.
Release park brake and shift to 4th forward.
Drive machine at approximately 1200 rpm and press Quick Shift Switch once.
LOOK/FEEL: Does transmission shift to and remain in 3rd gear?
LOOK/FEEL: Does transmission shift to and remain in 2nd gear?
LOOK/FEEL: Does transmission shift to and remain in 1st gear?
LOOK/FEEL: Does transmission stay in 1st gear?
NOTE: In DOWN ONLY mode pressing Quick Shift Switch will not change gears once
1st gear is reached, unless a direction or gear change is made.
– – –1/1

092005
PN=36
Transmission Shift Mode Press automatic transmission switch to place YES: Go to next check.
Check (S.N. 590068— ) transmission in manual mode. LED is off.
NO: Check restriction
Press MENU to bring up the main menu, select Machine switch/radio ignition
A Settings (2), then Quick Shift (1). power 10 A fuse (F11).
See Fuse and Relay
9005
Press SELECT to set quick shift in Down/Up mode. Specifications (S.N.
10
590068— ). (Group
11
T194310 –UN–11SEP03 Release park brake and shift to 3rd forward. 9015B-10.)
Drive machine at approximately 1600 rpm and press NO: Check Quick Shift
Quick Shift Switch once. Switch. See Transmission
Control Unit (TCU) Circuit
NOTE: On machines equipped with single lever pilot Theory of Operation (S.N.
controls, the quick shift switch is the raised switch on the 590068— ). (Group
top of the controller. On machines equipped with two 9015B-15.)
lever pilot controls, the quick shift switch is located on
the top of the boom (left) pilot control.
LOOK/FEEL: Does transmission shift to and remain in

2nd gear?
LOOK/FEEL: Does transmission shift back to 3rd gear?
NOTE: If Quick Shift Switch is pressed twice,

transmission will shift down one gear then immediately
back up to where it was. Quick Shift feature operates in
all gears.
Press MENU to bring up the main menu, select Machine

Settings (2), then Quick Shift (1).
Press NEXT to highlight Down Only then press SELECT

to set quick shift in Down only mode.
Release park brake and shift to 4th forward.
Drive machine at approximately 1200 rpm and press

Quick Shift Switch once.

3rd gear?

2nd gear?

1st gear?
LOOK/FEEL: Does transmission stay in 1st gear?
NOTE: In DOWN ONLY mode pressing Quick Shift

Switch will not change gears once 1st gear is reached,
unless a direction or gear change is made.
– – –1/1

092005
PN=37
Transmission Shift Disable clutch cut-off. YES: Go to next check.

Modulation Check
Enable manual transmission mode. NO: See Transmission
Shifts Too Slow or See
Transmission Shifts Too
CAUTION: Fasten seat belt before performing this check. Machine will Fast. (Group 9020-15.)
9005 change directions abruptly!
10
12 Shift transmission to 1st forward, increase engine speed to fast idle, shift from forward
to reverse and reverse to forward several times, allowing machine to reach full speed
in forward and reverse before changing directions. Repeat check in 2nd gear.
LOOK: Does machine slow down and change direction smoothly?
Drive machine in 2nd gear at high idle, apply service brakes to slow engine down to
1800 rpm, then while still holding service brakes, shift to 1st gear.
FEEL: Does transmission shift smoothly without jerking?
– – –1/1
Torque Converter and Park brake released. YES: Go to next check.

Engine Power Check
Turn Clutch Cut-Off Switch to off. NO: If stall speed is
outside range, problem
Apply service brakes so machine does not move. may be engine power or
torque converter. See
Shift transmission to 3rd forward. Engine Power Test Using
Turbocharger Boost
T106883 –UN–14FEB97
Push accelerator pedal until it touches stop bolt. Record Pressure. (Group
engine speed in basic display window. 9010-25.)
LOOK: Is torque converter stall speed within following IF OK: If power is ok, see
range: Diagnose Transmission
System Malfunctions.
• No. 1 fuel: 2040—2170 rpm (Group 9020-15.)
• No. 2 fuel: 2070—2190 rpm
Move transmission control lever to neutral "N" position

and run for 15 seconds to cool oil.
– – –1/1

092005
PN=38
Axle Disconnect Check Operate machine in an open area away from bystanders. YES: Go to next check.
(If Equipped)
With bucket partially dumped, lower boom to raise front NO: Check Differential
wheels off the ground. Lock and Pin Disconnect
Fuse. See Fuse And
Enable axle disconnect. Relay Specifications
9005
(S.N. —590067). (Group
10
Watch front wheels while operating the machine in 9015A-10.)
13
reverse. Front wheels must not rotate as machine moves
T6601AA –UN–19OCT88
backwards. NO: Check axle
disconnect circuit. See
LOOK: Do front wheels remain stationary while machine Flex Load Controller
moves backwards? (FLC) Circuit Theory of
). (Group 9015B-10.)
IF OK: See Diagnose

Differential Axle
9020-15.)
– – –1/1
Differential Lock Check Park unit on a hard surface. YES: Go to next check.
Release brakes. NO: Check differential

lock circuit. See System
Push Differential Lock Switch and steer unit left and Functional Schematic
right. (S.N. —590067). (Group
9015A-15.) See Flex
Release switch and steer unit left and right. Load Controller (FLC)
Circuit Theory of
LOOK: Do front wheels slide with differential lock on? Operation (S.N. 590068—
). (Group 9015B-15.)
NOTE: It is normal to get a "clunk" sound when you
release switch. NO: See Differential Lock
Pressure Test. (Group
LOOK: Do front wheels rotate in opposite directions with 9025-20.)
differential lock switch released?
T103168 –UN–05SEP96
– – –1/1

092005
PN=39
Service Brake Pressure Stop engine. YES: Go to next check.

Switch And Brake
Accumulator Precharge Hold Pilot Enable/Boom Down Switch in DOWN position and cycle control lever in all NO: If brake oil pressure
(S.N. —590067) directions 20 times to bleed charge pressure from PRV/brake accumulator. indictor does not come
on, See Monitor Display
Key switch on. Do not start engine. Unit Theory of Operation.
9005
(Group 9015A-15.)
10
Press brake pedal and record number of applications until brake pressure indicator
14
comes on. NO: If brake lights fail to
come on, check Brake
Continue pushing brake pedal and counting applications until brake lights fail to come Light Pressure Switch
on. (B40) See Electrical
Component Specification
LOOK: Are at least 12 brake pedal applications needed before brake pressure For Switch Specifications
indicator comes on? (S.N. —590067). (Group
9015A-20.)
LOOK: Are at least 30 brake pedal applications needed before brake lights fail to come
on? IF OK: If fewer than 12
brake pedal applications
are required to turn brake
oil pressure indicator on,
accumulator charge
pressure may be low.
See Service Brake
Accumulator Precharge
Test. (Group 9025-25.)
– – –1/1
Service Brake Pressure Stop engine. YES: Go to next check.

Switch And Brake
Accumulator Precharge Turn key to on position. NO: If brake oil pressure
(S.N. 590068— ) indictor does not come
Press and hold Pilot Enable/Boom Down Switch and on, check Service Brake
cycle hydraulic control lever in all directions 20 times to Accumulator Charge
bleed charge pressure from PRV/brake accumulator. Pressure Switch (B27).
See Electrical Component
T194312 –UN–11SEP03 Press brake pedal and record number of applications Specifications (S.N.
until brake pressure indicator comes on. 590068— ) (Group
9015B-20.)
Continue pushing brake pedal and counting applications
until brake lights fail to come on. NO: If brake lights fail to
come on, check Brake
LOOK: Are at least 12 brake pedal applications needed Light Pressure Switch
before brake pressure indicator comes on? (B40). See Electrical
Component Specifications
LOOK: Are at least 30 brake pedal applications needed (S.N. 590068— ). (Group
before brake lights fail to come on? 9015B-20.)
IF OK: If fewer than 12

brake pedal applications
are required to turn brake
oil pressure indicator on,
accumulator charge
pressure may be low.
See Brake Accumulator
Precharge Test. (Group
9020-10.)
– – –1/1

092005
PN=40
Pilot Controller Lock YES: Go to next check.

Check (S.N. —590067)
NO: Check Pilot
Enable/Boom Down
Switch and circuit. See
Load Center Harness
9005
(W3) Component
10
Location (S.N. —590067).
15
T103429 –UN–09SEP96 (Group 9015A-10.)
T107029 –UN–04FEB97
Run machine at idle.
Push Pilot Enable/Boom Down Switch to locked position.
Hold boom control lever in boom raise position.
Move Pilot Enable/Boom Down Switch to unlock and observe boom.
LOOK: Does boom raise when switch is unlocked?
Move Pilot Enable/Boom Down Switch to locked position and observe boom.
LOOK: Does boom stop when switch is locked?
Unlock Pilot Enable/Boom Down Switch and check all hydraulic functions.
• Boom Up/Down
• Bucket Roll/Dump
• Auxiliary functions (if equipped)
• Steering (Left and Right)
• Pin Disconnect (if equipped)
– – –1/1

092005
PN=41
Pilot Controller Lock YES: Go to next check.

Check (S.N. 590068— )
NO: Check Pilot
Enable/Boom Down
Switch and circuit. See
Flex Load Controller
9005
(FLC) Circuit Theory of
10
16
T194312 –UN–11SEP03 T103429 –UN–09SEP96 ). (Group 9015B-15.)
Run machine at idle. NO: See Diagnose

Hydraulic System
Press Pilot Enable/Boom Down Switch to lock the pilot controls (LED unlit). Malfunctions. (Group
9025-15.)
Hold control lever in boom raise position.
Press Pilot Enable/Boom Down Switch to unlock the pilot controls (LED illuminated).
LOOK: Does boom raise when pilot controls are unlocked?
Press Pilot Enable/Boom Down Switch to lock the pilot controls (LED unlit) and
observe boom.
LOOK: Does boom stop when controls are locked?
Unlock pilot controls and check all hydraulic functions.
• Boom Up/Down
• Bucket Roll/Dump
• Auxiliary functions (if equipped)
• Steering (Left and Right)
• Pin Disconnect (if equipped)
LOOK: Do all equipped hydraulic functions operate correctly?
– – –1/1
Pilot Enable/Boom Down Raise boom. YES: Go to next check

Solenoid Check (S.N. —
590067) Stop engine. NO: Check Boom Down
Fuse (F28) (dome light
Turn key to on position. will not work if fuse is
blown).
Hold Pilot Enable/Boom Down Switch in DOWN position.
See Fuse And Relay
Specifications (S.N. —
T107030 –UN–04FEB97
CAUTION: Prevent possible injury from 590067). (Group
crushing. Keep area under boom clear. Boom 9015A-10.)
will lower quickly to ground.
IF OK: Check Boom
Move control lever to boom lower position. Down Solenoid (Y15).
See Engine Frame
LOOK: Does boom lower? Harness (W5) Component
(Group 9015A-10.)
– – –1/1

092005
PN=42
Pilot Enable/Boom Down Raise boom. YES: Go to next check.

Solenoid Check (S.N.
590068— ) Stop engine. NO: Check Boom Down
Accumulator Solenoid
Turn key to on position. (Y15). See Engine Frame
Harness (W5) Component
9005
Press and hold Pilot Enable/Boom Down Switch. Location (S.N. 590068—).
10
(Group 9015B-10.)
17
T194312 –UN–11SEP03
CAUTION: Boom will quickly lower to
ground.
Move control lever to boom lower position.
LOOK: Does boom lower?
– – –1/1
Pilot Control Valve Boom YES: Go to next check.

Float Check
NO: See Pressure
Reducing Valve Pressure
T107137 –UN–07FEB97
T194313 –UN–11SEP03 T194315 –UN–11SEP03
Run engine at slow idle.
Push Ride Control Switch off.
Push Return-to-Carry Switch off.
With the bucket partially dumped, lower boom to raise front of machine.
Push control lever to the float detent position and release lever.
LOOK: Does front of machine lower to the ground and valve remain in float position
when lever is released?
– – –1/1

092005
PN=43
Return-to-Dig Check Raise the boom to about eye level. YES: Go to next check.
Fully dump the bucket. NO: Verify that the

sensor is adjusted
Verify that return-to-dig function is turned on. correctly. See
Return-to-Dig Adjustment
9005
Place controller in the bucket load detent position. (S.N. —590067). (Group
10
9015A-20.) See
18
LOOK/FEEL: Does pilot controller detent? Return-to-Dig Adjustment
(S.N. 590068— ). (Group
LOOK: Does bucket travel stop upon reaching dig position? 9015B-20.)
NO: Check return-to-dig

circuit. See
Return-to-Carry,
Boom-Height-Kickout And
Return-To-Dig Circuit
Theory Of Operation
(S.N. —590067) (Group
9015A-15.) See Flex
Load Controller (FLC)
Circuit Theory of
). (Group 9015B-15.)
– – –1/1
Return-to-Carry Check Fully raise boom. YES: Go to next check.
Place bucket in dig position. NO: Verify that the

sensor is adjusted
Verify that the return-to-carry function is turned on. correctly. See
Return-To-Carry Kickout
Place controller in the boom down detent position. Adjustment (S.N. —
590067). (Group
LOOK/FEEL: Does pilot controller detent? 9015A-20.) See Boom
Height
LOOK: Does boom travel stop upon reaching carry position? Kickout/Return-to-Carry
Adjustment (S.N.
590068— ). (Group
9015B-20.)
NO: Check return-to-carry

circuit. See
Return-to-Carry,
Theory Of Operation
(S.N. —590067) (Group
9015A-15.) See Flex
Circuit Theory of
). (Group 9015B-15.)
– – –1/1

092005
PN=44
Boom Height Kickout Lower boom to the ground. YES: Go to next check.
Check
Place bucket in dig position. NO: Verify that the
sensor is adjusted
Verify that boom height kickout function is turned on. correctly. See
Boom-Height-Kickout
9005
Place controller in the boom up detent position. Adjustment (S.N. —
10
590067). (Group
19
LOOK/FEEL: Does pilot controller detent? 9015A-20.) See Boom
Height
LOOK: Does boom travel stop before reaching full height? Kickout/Return-to-Carry
Adjustment (S.N.
590068— ). (Group
9015B-20.)
NO: Check boom height

kickout circuit. See
Return-to-Carry,
Theory Of Operation
(S.N. —590067) (Group
9015A-15.) See Flex
Circuit Theory of
). (Group 9015B-15.)
– – –1/1
Pin Disconnect System Run engine at slow idle. YES: Go to next check.
Check (If Equipped)
(S.N. —590067) Position bucket flat on the ground. NO: Check Differential
Lock and Pin Disconnect
Push and hold Pin Disconnect Switch (DETACH). Fuse (F14). See Fuse
And Relay Specifications
LOOK: Does pin disconnect cylinder retract both pins while switch is pressed? (S.N. —590067). (Group
9015A-10.)
NO: Hold a screwdriver

blade against the end of
the pin disconnect
solenoid. Check for
magnetism with the
switch pushed, if
magnetism switch is ok.
IF OK: See Diagnose

Loader Hydraulic System
9025-15.)
– – –1/1

092005
PN=45
Pin Disconnect System Run engine at slow idle. YES: Go to next check.
Check (If Equipped) (S.N.
590068— ) Position bucket flat on the ground. NO: Verify that function is
enabled in CAN Monitor
Push and hold Pin Disconnect Switch on the sealed Unit (CMU) machine
switch module (SSM). configuration.See CAN
9005
Monitor Unit (CMU)
10
LOOK: Does pin disconnect cylinder retract both pins Circuit Theory of
20
T194317 –UN–11SEP03 while switch is pressed? Operation (S.N. 590068—
). (Group 9015B-15.)
NO: Check the pin

disconnect circuit. See
Flex Load Controller
(FLC) Circuit Theory of
). (Group 9015B-15.)
IF OK: See Diagnose

9025-15.)
– – –1/1
Ride Control Check YES: Go to next check.

(S.N. —590067) CAUTION: Boom will jump upward during this check. Make sure area
around bucket is clear. NO: Check Ride Control
Fuse (F30). (Group
Push Ride Control Switch to off position. 9015A-10.) See Fuse And
Raise boom to maximum height and hold control lever Relay Specifications
over relief for 2 seconds. (S.N. —590067). (Group
9015A-10.)
Lower boom and bucket to eye level. Observe loader
boom as Ride Control Switch is switched to on. Check Ride Control
Switch using continuity
LOOK/FEEL: Does boom jump upward 30 cm (12 in) or check through Monitor in
T107137 –UN–07FEB97
more? Continuity Check (D02).
See Monitor Display
Push ride control switch to AUTO position. Switch will Unit—Diagnostics Menu
light. (S.N. —590067). (Group
9015A-15.)
Raise boom to maximum height and hold control lever
over relief for 2 seconds. NO: Check Ride Control
Boom Solenoid and Ride
Lower boom and bucket to eye level and slowly Control (On/Off) Solenoid.
accelerate to 5 mph while watching speedometer and See Ride Control
bucket. Harness (W9) Component
LOOK/FEEL: Does ride control come on at (Group 9015A-10.)
approximately 3 mph and bucket raise slightly?
T107037 –UN–07FEB97
IF OK: Check ride control
accumulator charge
pressure. See Charge
Ride Control Accumulator
. (Group 9025-20.)
IF OK: Check valve or

solenoid valve in ride
control manifold is stuck
open. See Ride Control
Valve Remove And Install
(S.N. —590067). (Group
3160.)
– – –1/1

092005
PN=46
Ride Control Check (S.N. YES: Go to next check.

590068— ) CAUTION: Boom will jump upward during
this check. Make sure area around bucket is NO: Check ride control
clear. circuit. See Flex Load
Controller (FLC) Circuit
Turn ride control off by pressing the ride control switch Theory of Operation (S.N.
until no LEDs are lit. 9005
590068— ). (Group
10
9015B-15.)
Raise boom to maximum height and hold control lever 21
T194313 –UN–11SEP03
over relief for 2 seconds. NO: Verify that function is
Lower boom and bucket to eye level. Press ride control Unit (CMU) machine
switch once to enable manual mode and observe loader configuration. See CAN
boom. Monitor Unit (CMU)
Circuit Theory of
LOOK/FEEL: Does boom jump upward 30 cm (12 in) or Operation (S.N. 590068—
more? ). (Group 9015B-15.)
Press ride control switch on the SSM once more to IF OK: Check ride control
enable auto mode. Right LED will illuminate. accumulator charge
pressure. See Charge
Raise boom to maximum height and hold control lever Ride Control
over relief for 2 seconds. Accumulator. (Group
9025-20.)
Lower boom and bucket to eye level and slowly
accelerate to 5 mph while watching speedometer and IF OK: Check valve or
bucket. solenoid valve in ride
control manifold is stuck
LOOK/FEEL: Does ride control come on at open. See Ride Control
approximately 3 mph and bucket raise slightly? Valve Remove And Install
(S.N. —590067). (Group
3160.)
– – –1/1

092005
PN=47
Spin Control Check (If A—Spin Control Mode Switch YES: Go to next check.
Equipped) (S.N. — B—Spin Control Switch
590067) NO: Check Spin Control
Run engine at high idle. Switch through Continuity
Check (D02) in monitor.
Transmission in first forward. See Monitor Display
9005
Unit—Diagnostics Menu
10
Drive ahead in an open clear area (S.N. —590067). (Group
22
T103451 –UN–05SEP96 9015A-15.)
Turn knob (A) to position 1 and turn Spin Control Switch
(B) to on position
Hold lever in roll back position.
LOOK/LISTEN: Does engine rpm drop?
NOTE: The engine rpm will remain at lower level until

transmission control lever is shifted through neutral
position or Spin Control switch is turned OFF.
Turn Spin Control switch to off position.
Hold lever in roll back position. Note engine rpm drop as

hydraulic system is at high standby pressure.
Repeat for switch positions 2—5.
The rpm drop in each position is:
• 1—1900
• 2—1825
• 3—1750
• 4—1675
• 5—1600
– – –1/1

092005
PN=48
Spin Control Check (If Run engine at high idle. YES: Go to next check.
Equipped) (S.N. 590068—
) Transmission in first forward. NO: Verify that function is
Drive ahead in an open clear area Unit (CMU) machine
configuration. See CAN
9005
Press spin control switch once. First LED will illuminate. Monitor Unit (CMU)
10
Circuit Theory of
23
T194320 –UN–11SEP03 Hold lever in roll back position. Operation (S.N. 590068—
). (Group 9015B-15.)
LOOK/LISTEN: Does engine rpm drop?
NO: Check spin control
NOTE: The engine rpm will remain at lower level until circuit. See Flex Load
transmission control lever is shifted through neutral Controller (FLC) Circuit
position or spin control switch is turned OFF. Theory of Operation (S.N.
590068— ). (Group
Press spin control switch until function is disabled. All 9015B-15.)
LEDs are unlit.
Hold lever in roll back position. Note engine rpm drop as

hydraulic system is at high standby pressure.
Repeat for switch positions 2—4.
The rpm drop in each position is:
• 1—1900
• 2—1800
• 3—1700
• 4—1600
– – –1/1
Reverse Fan Check (If Press the reverse fan switch to activate manual mode YES: Go to next check.
Equipped) (LED illuminated).
NO: Verify that function is
NOTE: Reverse fan function cannot be operated twice enabled in CAN Monitor
within 1 minute. Wait 1 minute before attempting to Unit (CMU) machine
reverse fan direction again. configuration.See CAN
Monitor Unit (CMU)
LISTEN/LOOK: Does fan reverse direction and operate Circuit Theory of
T194319 –UN–11SEP03 at full speed for 15 seconds? Operation (S.N. 590068—
). (Group 9015B-15.)
Fan will change directions and operate at normal speed.
NO: Check reverse fan
circuit and proportional
fan circuit. See Flex Load
Theory of Operation (S.N.
590068— ). (Group
9015B-15.)
IF OK: Check fan

hydraulic circuit. See Fan
Drive Operation. (Group
9025-05.)
– – –1/1

092005
PN=49
Proportional Fan Check Press and hold the MENU button on the CAN Monitor Unit (CMU) for 5 seconds to YES: Go to next check.
(If Equipped) enter the service menu.
NO: Verify that function is
Press NEXT until Machine Config is highlighted and press SELECT. enabled in CAN Monitor
Unit (CMU) machine
Press NEXT until Fan Speed % is highlighted and press SELECT. configuration. See CAN
9005
Monitor Unit (CMU)
10
Press SELECT to manually set the fan speed to 0%. The CMU will confirm the Circuit Theory of
24
selection. Operation (S.N. 590068—
). (Group 9015B-15.)
LOOK/FEEL: Take notice of fan speed.
NO: Check proportional
Press BACK then SELECT to manually set the fan speed to 100%. fan circuit. See Flex Load
LOOK/FEEL: Is the fan speed higher than at 0%? Theory of Operation (S.N.
590068— ). (Group
9015B-15.)
IF OK: Check fan

hydraulic circuit. See Fan
Drive Operation. (Group
9025-05.)
– – –1/1
Boom And Bucket Set bucket flat on the ground and raise about 50 mm (2 YES: Go to next check.
Cylinder Drift Check in.).
NO: See Boom and
Stop engine. Observe bucket for 1 minute. Bucket Cylinder Leakage
Test to isolate cylinder or
LOOK: Does bucket remain in position? Bucket should valve leakage. (Group
not settle to the ground. 9025-25.)
T6564NZ –UN–19OCT88
NOTE: Use good judgement to determine if the amount
of drift is objectionable for your loader application.
– – –1/1
Steering Valve Check Transmission in Neutral. YES: Go to next check.
Run engine at low idle. NO: See Steering Valve

Leakage Test. (Group
Remove foot from brake pedal. 9025-25.)
Release park brake.
T6471AQ –UN–19OCT88
Turn steering wheel until machine frames contact right
and left frame stops.
LOOK: Does machine steer smoothly in both directions?
NOTE: It is normal for machine frames to drift away from

frame stops when steering wheel is released.
When steering wheel is stopped, frames must stop.
FEEL: Is excessive effort required to turn steering

wheel?
– – –1/1

092005
PN=50
Secondary Steering IMPORTANT: Do not operate secondary steering pump for more than 15 seconds YES: Go to next check.
System Check (If with the steering in neutral or damage to the pump and motor can occur.
Equipped) (S.N. — NO: Check Secondary
590067) Park unit on a hard level surface with machine frames straight. Steering and Start Aid
Fuse (F2).
Remove Engine Controller Switched Fuse (F6). See Fuse And Relay Specifications
9005
(S.N. —590067). (Group 9015A-10.) NO: Check secondary
10
steering circuit. See
25
Secondary steering will activate. Secondary Steering
Circuit Theory Of
Steer unit to right and left. Operation (S.N. —
590067). (Group
LOOK: Does machine steer approximately half way to stops in both directions? Does 9015A-15.)
light in monitor come on and stay on until key is turned off?
IF OK: If secondary
steering pump and motor
operate but machine does
not steer, see Secondary
Steering Pump Relief
Valve Pressure Test.
(Group 9025-25.)
– – –1/1
Secondary Steering IMPORTANT: Do not operate secondary steering pump for more than 15 seconds YES: Go to next check.
System Check (If with the steering in neutral or damage to the pump and motor can occur.
Equipped) (S.N. 590068— NO: Verify that function is
) Park unit on a hard level surface with machine frames straight. enabled in CAN Monitor
Unit (CMU) machine
Remove ECU ignition power 5 A fuse (F10) from Vehicle Electrical Center (VEC). configuration. See CAN
Monitor Unit (CMU)
Secondary steering will activate. Circuit Theory of
Steer unit to right and left. ). (Group 9015B-15.)
LOOK: Does machine steer approximately half way to stops in both directions? Does NO: Check secondary
light in monitor come on and stay on until key is turned off? steering circuit. See Flex
Circuit Theory of
). (Group 9015B-15.)
IF OK: If secondary
steering pump and motor
operate but machine does
not steer, see Secondary
Steering Pump Relief
Valve Pressure Test.
(Group 9025-25.)
– – –1/1

092005
PN=51
Cycle Time Test Check Use the monitor unit or SERVICE ADVISOR™ application to read engine rpm and YES: Operational
hydraulic oil temperature. Checkout complete.
Specification NO: Check pilot pressure.

Hydraulic Oil—Temperature ............................................................................... 44—56°C See Pilot Control Valve
110—130°F Pressure Test. (Group
9005
9025-25.)
10
Engine Fast Idle—Specification
26
644J—Speed .......................................................................................... 2325—2375 rpm IF OK: Check hydraulic
724J—Speed .......................................................................................... 2325—2375 rpm pump. See Hydraulic
Pump Flow Test. (Group
Boom Raise—Specification 9025-25.)
644J—Cycle Time .......................................................................................... 6.8 seconds
Boom Lower (Float)—Specification

Bucket Dump (Boom at Full Height)—Specification

Steering (Stop to Stop)—Specification

Steering Wheel Revolutions ................................................................................. 3.5—4.5
Steering Wheel Revolutions ................................................................................. 3.0—4.0
Are cycle times faster than specification?

092005
PN=52
Section 9010
Engine
Contents
Page

POWERTECH® 8.1L (6081) John Deere 9010
Engines . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-1
Engine Air Heater Circuit Operation (S.N. —
590067) . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-2
Engine Air Heater Circuit Theory of
Operation (S.N. 590068— ) . . . . . . . . . . . .9010-05-3
Electronic Fuel Injection System
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-4

Diagnose Engine Malfunctions . . . . . . . . . . .9010-15-1
Group 25—Tests
Fuel Line Leakage Test. . . . . . . . . . . . . . . . .9010-25-1
Air Intake System Leakage Test . . . . . . . . . .9010-25-3
Air Filter Restriction Indicator Switch Test . . .9010-25-4
Engine Power Test Using Turbocharger
Boost Pressure . . . . . . . . . . . . . . . . . . . . .9010-25-4

092005
PN=1
Contents
9010

092005
PN=2
Group 05
Theory Of Operation
POWERTECH® 8.1L (6081) John Deere

Engines
For additional information on John Deere engines and

components, see the following Component Technical
Manuals.
• PowerTech 8.1L Diesel Engines Base Engine. (CTM86.)

• PowerTech 8.1L Diesel Engines Level 9 Electronic Fuel
System with Denso HPCR. (CTM255.)
• Alternators and Starting Motors. (CTM77.) 9010
05
1
POWERTECH is a trademark of Deere & Company MF82180,0000170 –19–26NOV03–1/1

092005
PN=55
Theory Of Operation
Engine Air Heater Circuit Operation (S.N. —590067)
IMPORTANT: DO NOT use fluid starting aid option If battery voltage drops below 20 V, the ECU will turn
with the engine air heater. Damage off the air heaters. This allows air heaters to be OFF
to engine may occur. during cranking. Air heaters will turn back on then
when the battery voltage raises above 20 V.
The engine air heater function allows for easier cold
weather starting and also helps reduce black smoke Air heaters have a large amperage demand. Battery
shortly after engine start-up. Air heater is controlled by power is supplied to the Engine Air Heater Relay (K34)
the Engine Control Unit (ECU). through a 125 A Fuse (F36) located in the engine
9010 compartment. See Engine Air Heater Harness (W7)
05 When the key switch is turned on the Engine Control Component Location (S.N. —590067). (Group
2
Unit (ECU) (A1) measures engine manifold air 9015A-10.)
temperature. The ECU calculates the air heater on
time for both preheat (before start-up) and postheat Power to energize Engine Air Heater Relay (K34) coil
(after start-up) based on the recorded manifold air comes from the Engine Air Heater Coil Relay (K33)
temperature. Engine Preheat Indicator Light will come when commanded by the ECU. The ECU also send a
on in monitor display when air heaters are on. signal across the Controller Area Network (CAN) bus
Operator should wait for the light to go out before to the monitor display unit to illuminate the engine
starting the machine. preheat indicator light.
On times for preheat and postheat are independent of Details for components in air heater circuit are in
one another. On time is longer at colder temperatures. system functional schematic section SE2. See System
Maximum preheat on time is 30 seconds. Maximum on Functional Schematic (S.N. —590067). (Group
time for post heat is 60 seconds. 9015A-10.)
Manifold air temperature has to be less than 10° C NOTE: Anytime the key is moved from Start to Run
(50° F) for air heaters to come on during preheat. position when engine does not start, a
Manifold air temperature has to be less than 20° C key-off/key-on cycle will be required before
(68° F) for air heaters to come on during postheat. preheating is allowed again.
CED,TX17864,25 –19–16SEP02–1/1

092005
PN=56
Theory Of Operation
Engine Air Heater Circuit Theory of Operation (S.N. 590068— )
IMPORTANT: Do not use fluid starting aid option colder temperatures and shorter at warmer
with the engine air heater. Damage temperatures. The maximum preheat on time is 10
to engine may occur. seconds. The maximum on time for post heat is 60
seconds.
See SE2 Alternator and Engine Air Heater Circuit in
the System Functional Schematic and Schematic The coolant temperature must be less than 10°C
Legend (S.N. 590068— ) for more information. (Group (50°F) for the air heaters to come on during preheat.
9015B-10.) The coolant temperature has to be less than 20°C
(68°F) for the air heaters to come on during postheat. 9010
The following conditions must be met for the engine air 05
3
heater circuit to operate: The ECU also monitors battery voltage. If voltage
drops below 20 volts, the ECU disables the air
• Key switch (S1) at On or Start heaters. This allows the air heaters to be OFF during
• Battery voltage higher than 20 volts engine start. The air heaters will go on when the
• Temperature below 10° C (50° F) for preheat battery voltage is above 20 volts.
• Temperature below 20° C (68° F) for postheat
• Power to Engine Control Unit (A1) Unswitched power flows from the batteries to starter
motor (M1) and engine air heater 125 A fusible link
The engine air heater function allows for easier cold (F65) to the engine air heater relay (K5).
weather starting and helps reduce black smoke shortly
after engine start-up. When the key switch is turned The ECU battery voltage output (J3) energizes engine
On, the Engine Control Unit (ECU) initializes. During air heater relay (K5). Battery power is then supplied to
initialization, the ECU (A1) measures and records heaters (E26—E28) for operation. The ECU also
engine coolant temperature. It then calculates the air broadcasts a message across the Controller Area
heater on time for preheat (before start-up) and Network (CAN) to illuminate the engine preheat
postheat (after start-up), based on recorded coolant indicator on the CMU.
temperature. The engine preheat indicator will come
on in the CAN Monitor Unit (CMU) when the air NOTE: Any time the key moves from Start to On
heaters are on. The light should be out before position and the engine does not start, cycle
attempting to start the machine. the key OFF and on to continue preheat.
The on times for preheat and postheat are

independent of one another. The on time is longer at
MF82180,0000171 –19–26NOV03–1/1

092005
PN=57
Theory Of Operation
Electronic Fuel Injection System Operation
See Fuel System Operation in CTM255.
See Electronic Control System Overview in CTM255.
See Electronic Control System Operation in CTM255.
See High Pressure Fuel Pump Operation in CTM255.
9010 See High Pressure Common Rail (HPCR) Operation in

05 CTM255.
4
CED,TX17864,26 –19–26JUN02–1/1

092005
PN=58
Group 15
Diagnostic Information
Diagnose Engine Malfunctions
See Engine Diagnostic Trouble Codes (S.N. —590067)

(Group 9015A-20.) or See Engine Control Unit (ECU)
Diagnostic Trouble Codes (S.N. 590068— ) (Group
9015B-20.)
Symptom Problem Solution
Engine Cranks/Won’t Start Engine Problem For engines with a Level 9 ECU, see
LEVEL 9 ECU - E1 - ENGINE 9010
CRANKS/WON’T START 15
1
DIAGNOSTIC PROCEDURE in
Section 04, Group 150 of CTM255.
Engine Misfires/Runs Irregularly Engine Problem For engines with a Level 9 ECU, see
LEVEL 9 ECU - E2 - ENGINE
MISFIRES/RUNS IRREGULARLY
Engine Does Not Develop Full Engine Problem For engines with a Level 9 ECU, see
Power LEVEL 9 ENGINE DOES NOT
DEVELOP FULL POWER
Engine Emits Excessive White Engine Problem For engines with a Level 9 ECU, see
Exhaust Smoke LEVEL 9 ECU - E4 - ENGINE
EMITS EXCESSIVE WHITE
EXHAUST SMOKE DIAGNOSTIC
PROCEDURE in Section 04, Group
150 of CTM255.
Engine Emits Excessive Black Or Engine Problem For engines with a Level 9 ECU, see
Gray Smoke LEVEL 9 ECU - E5 - ENGINE
EMITS EXCESSIVE BLACK OR
GRAY SMOKE DIAGNOSTIC
150 of CTM255.
Engine Will Not Crank Engine Problem For engines with a Level 9 ECU, see
LEVEL 9 ECU - E6 - ENGINE WILL
NOT CRANK in Section 04, Group
150 of CTM255.
Continued on next page CED,TX17864,27 –19–24MAR98–1/2

092005
PN=59
Engine Idles Poorly Engine Problem For engines with a Level 9 ECU, see
LEVEL 9 ECU - E7 - ENGINE IDLES
POORLY in Section 04, Group 150
of CTM255.
Abnormal Engine Noise Engine Problem For engines with a Level 9 ECU, see
LEVEL 9 ECU - E8 - ABNORMAL
ENGINE NOISE in Section 04,
9010 Group 150 of CTM255.
15
2
Excessive Oil Consumption Engine Problem For 8.1L engines, see 8.1L - L1 -
EXCESSIVE OIL CONSUMPTION in
Engine Oil Pressure Low Engine Problem For 8.1L engines, see 8.1L - L2 -
ENGINE OIL PRESSURE LOW in
Engine Oil Pressure High Engine Problem For 8.1L engines, see 8.1L - L3 -
ENGINE OIL PRESSURE HIGH in
Engine Coolant Temperature Engine Problem For 8.1L engines, see 8.1L - C1 -
Above Normal ENGINE COOLANT
TEMPERATURE ABOVE NORMAL
in Section 04, Group 150 of CTM86.
Engine Coolant Temperature Engine Problem For 8.1L engines, see 8.1L - C2 -
Below Normal ENGINE COOLANT
TEMPERATURE BELOW NORMAL
in Section 04, Group 150 of CTM86.
Coolant In Oil or Oil In Coolant Engine Problem For 8.1L engines, see 8.1L - C3 -
COOLANT IN OIL OR OIL IN
COOLANT in Section 04, Group 150
of CTM86.
CED,TX17864,27 –19–24MAR98–2/2

092005
PN=60
Group 25
Tests
Fuel Line Leakage Test
SPECIFICATIONS
Fuel System Test Pressure 69 kPa
0.7 bar
10 psi
SERVICE EQUIPMENT AND TOOLS

Pressure Regulator
Connections may allow air to enter the fuel system without 9010
allowing fuel to leak out. Follow this procedure to find air 25
1
leaks in the system.
1. Disconnect fuel supply and fuel return lines at fuel

tank.
2. Drain all fuel from system, including fuel supply pump,

fuel injection pump, and fuel filters.
3. Close end of fuel return line using a plug, cap, or a

short length of hose, plug, and clamps.
IMPORTANT: Never exceed 103 kPa (1 bar) (15 psi) to

prevent damage to fuel system
components.
4. Pressurize the system at the fuel supply line using a

regulated pressure air source.
Specification
Fuel System Test—Pressure .......................................................... 69 kPa
0.7 bar
10 psi
5. Apply liquid soap and water solution to all joints and

connections in the fuel system and inspect for leaks.
6. Repair any leaks.
7. Connect supply and return lines and prime system.
8. Start machine and let run for approximately 10

minutes.
Continued on next page TX,1025,MM,140 –19–17MAR98–1/2

092005
PN=61
Tests
NOTE: For engines with an in-line fuel injection pump, an

internal leak path may allow air to enter the fuel
system. If an internal pump leak is suspected,
remove the pump and have a pressure test
performed by an authorized repair station.
9010
25
2 TX,1025,MM,140 –19–17MAR98–2/2

092005
PN=62
Tests
Air Intake System Leakage Test
SPECIFICATIONS
Air Intake System Pressure 14—21 kPa
Air Intake System 0.14—0.21 bar
Air Intake System 2—3 psi
–UN–23FEB89
ESSENTIAL TOOLS
JDE147 Manifold Pressure Kit
T5906AP
9010
SERVICE EQUIPMENT AND TOOLS 25
Pressure Regulator 3
OTHER MATERIAL
T43512 U.S. Thread Lock and Sealer (Medium Strength)
TY9473 Canadian Thread Lock and Sealer (Medium Strength)
242 LOCTITE® Thread Lock and Sealer (Medium Strength)
–UN–19MAR98
1. Remove air cleaner cover and main filter element.
2. Put large plastic bag into and over end of main filter
T114427B
element as shown. Install main filter element and
cover.
3. Remove plug from left side of intake manifold.
4. Connect air pressure regulator to manifold using hose

and fitting from manifold pressure tester.
5. Pressurize air intake system. If intake system cannot

be pressurized, turn engine slightly to close valves.
Specification
Air Intake System—Pressure .................................................. 14—21 kPa
0.14—0.21 bar
2—3 psi
6. Spray soap solution over all connections from the air

cleaner to turbocharger or air intake manifold and
check for leaks. Correct all leaks.
7. Apply thread lock and sealer (medium strength) to

plug. Install plug into intake manifold and tighten.
LOCTITE is a trademark of Loctite Corp. TX,901025,SS617 –19–21AUG91–1/1

092005
PN=63
Tests
Air Filter Restriction Indicator Switch Test
SPECIFICATIONS
Restriction Indicator Light Must 4.98—7.48 kPa (0.05—0.075 bar)
Come On Pressure (20—30 in. water)
ESSENTIAL TOOLS
JT0652 Tee
JT0246 Coupler
0202-4-4 Coupler (Parker)
9010
25
4 SERVICE EQUIPMENT AND TOOLS
Barbed Fitting (1/8 in.)
Barb Fitting (1/4 in.)
0—15 kPa (0—150 mbar) (0—60 in. Water) Vacuum Gauge
1. Remove air restriction indicator switch.
2. Install parts as shown.
–UN–17DEC90
3. Start engine and slowly cover the air cleaner inlet with
a piece of paper or cardboard.
T7350EP
4. Air filter restriction indicator (light) must come on
according to specification. Engine speed may need to
be increased above low idle with intake covered to
reach high range of specification. A—Switch
B—Tee
Specification C—Barbed Fitting
Restriction Indicator Light Must D—Tube
Come On—Pressure ............................ 4.98—7.48 kPa (0.05—0.075 bar) E—Barbed Fitting
(20—30 in. water) F—Coupler
G—Gauge
5. If reading is not within specifications, install a new
indicator switch.
TX,9010,SS530 –19–07JAN93–1/1
Engine Power Test Using Turbocharger Boost Pressure
SPECIFICATIONS SERVICE EQUIPMENT AND TOOLS

644J Turbocharger Boost 130—160 kPa JT07248 Manifold Pressure Test Gauge Kit
Pressure 1.3—1.6 bar
18—24 psi
This procedure should be used ONLY as a guide to
724J Turbocharger Boost 141—173 kPa
determine engine condition.
20—25 psi
Continued on next page CED,TX13067,22 –19–17APR00–1/3

092005
PN=64
Tests
1. Connect pressure gauge to intake manifold using hose

and fitting.
NOTE: Maximum boost pressure is obtained by pulling

engine down below rated speed, which will cause
pressure to drop, then slowly releasing load and
–UN–19MAR98
let engine slowly increase rpm. This cycle will
have to be repeated a minimum of six times in
succession to insure that maximum boost
pressure is obtained.
T114427B
9010
2. Warm engine and transmission to normal operating 25
5
temperature. Perform Transmission Oil Warm-Up
Procedure. (Group 9020-25.)
IMPORTANT: Do not overheat hydraulic or

transmission oil during this test,
converter stalls will rapidly increase
transmission temperature. Watch
transmission temperature gauge on
front dash, if it goes into red zone, stop
test until transmission cools to safe,
green zone.
3. Release park brake, apply service brake, shift to 3rd

forward gear and stall torque converter to warm
transmission oil to normal operating range on
temperature gauge.
With engine at operating temperature:
• Put transmission in 3rd gear forward. Hold service

brake, release park brake, and push accelerator
pedal to stop.
• Slowly move control lever into bucket curl and boom
down to pull down engine speed.
• Slowly return control lever to neutral.
Specification
644J Turbocharger Boost—
Pressure .............................................................................. 130—160 kPa
1.3—1.6 bar
18—24 psi
724J Turbocharger Boost—
Pressure .............................................................................. 141—173 kPa
1.41—1.73 bar
20—25 psi

092005
PN=65
Tests
4. Repeat Step 3 six times recording maximum reading

each time.
5. Compare highest reading to specification.
6. If boost pressure is low, remove muffler and verify

boost pressure.
If pressure is still low, check for the following:
9010 • Wrong fuel

25 • Restricted air filter elements
6
• Restricted fuel filter elements
• Incorrect fast idle adjustment
• Exhaust manifold leaks
• Intake manifold leaks
• Faulty fuel pump
• Low compression pressure
• Cam lobe wear (valve clearance)
• Carbon build-up in turbocharger
• Turbocharger compressor or turbine wheel rubbing
housing
• Faulty injectors
CED,TX13067,22 –19–17APR00–3/3

092005
PN=66
Section 9015A
Electrical System—724J (S.N. —590067)
Contents
Page Page
Group 05—System Information Cab Work Lights Harness (W19)

Electrical Diagram Information (S.N. — Component Location (S.N. —
590067) . . . . . . . . . . . . . . . . . . . . . . . . . 9015A-05-2 590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-55
Blower/Air Conditioning Harness (W20)
Group 10—System Diagrams And Component Location Drawing (S.N. —
Fuse and Relay Specifications (S.N. — 590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-57
590067) . . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-1 Converter And Power Plug Harness (W21) 9015A
System Functional Schematic Section Component Location (S.N. —
Legend (S.N. —590067) . . . . . . . . . . . . 9015A-10-2 590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-61
Functional Schematic And Component Secondary Steering Pump Motor Harness
Location Legend (S.N. —590067) . . . . . 9015A-10-3 (W23) Component Location (S.N. —
System Functional Schematic (S.N. — 590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-62
590067) . . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-8 Battery (Cables) Harness (W24)
Loader Frame Harness (W2) Component Component Location (S.N. —
Location (S.N. —590067) . . . . . . . . . . 9015A-10-22 590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-64
Load Center Harness (W3) Component Radio Harness (W34) Component Location
Location (S.N. —590067) . . . . . . . . . . 9015A-10-23 (S.N. —590067). . . . . . . . . . . . . . . . . . 9015A-10-65
Front Console Harness (W4) Component Electric Air Adjust Seat Harness (W36)
Location (S.N. —590067) . . . . . . . . . . 9015A-10-34 Component Location (S.N. —
Engine Frame Harness (W5) Component 590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-66
Location (S.N. —590067) . . . . . . . . . . 9015A-10-36 CAN Terminator Harness (W37)
Engine Harness (W6) Component Location Component Location (S.N. —
(S.N. —590067). . . . . . . . . . . . . . . . . . 9015A-10-38 590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-67
Engine Air Heater Harness (W7)
Component Location (S.N. — Group 15—Sub-System Diagnostics
590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-40 Start Circuit Theory Of Operation (S.N. —
Return-To-Dig Harness (W8) Component 590067) . . . . . . . . . . . . . . . . . . . . . . . . . 9015A-15-1
Location (S.N. —590067) . . . . . . . . . . 9015A-10-42 Ride Control Circuit Theory Of Operation
Ride Control Harness (W9) Component (S.N. —590067). . . . . . . . . . . . . . . . . . . 9015A-15-2
Location (S.N. —590067) . . . . . . . . . . 9015A-10-44 Monitor Display Unit Circuit Theory Of
Transmission Harness (W10) Component Operation (S.N. —590067) . . . . . . . . . . 9015A-15-4
Location (S.N. —590067) . . . . . . . . . . 9015A-10-46 Monitor Display Unit—Accessing Menus (S.N.
Rear Frame Harness (W13) Component —590067) . . . . . . . . . . . . . . . . . . . . . . . 9015A-15-8
Location (S.N. —590067) . . . . . . . . . . 9015A-10-48 Monitor Display Unit—Normal Display Menu
Spin Control Harness (W14) Component (S.N. —590067). . . . . . . . . . . . . . . . . . . 9015A-15-9
Location (S.N. —590067) . . . . . . . . . . 9015A-10-49 Monitor Display Unit—Accessory Menu (S.N.
License Plate Light Harness (W15) —590067) . . . . . . . . . . . . . . . . . . . . . . 9015A-15-11
Component Location (S.N. — Monitor Display Unit—Diagnostics Menu
590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-50 (S.N. —590067). . . . . . . . . . . . . . . . . . 9015A-15-19
Pin and Axle Disconnect Harness (W16) Monitor Display Unit—Service Menu (S.N. —
Component Location (S.N. — 590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-15-41
590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-52 Chassis Control Unit Circuit Theory Of
Secondary Steering Switch Harness Operation (S.N. —590067) . . . . . . . . . 9015A-15-51
(W17) Component Location (S.N. —
590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-54 Continued on next page
TM2075 (03MAR05) 9015A-1 644J and 724J Loader

092005
PN=1
Contents
Page Page
Spin Control Circuit Theory Of Operation Clutch Cut-Off Sensor Check and Adjustment
(S.N. —590067). . . . . . . . . . . . . . . . . . 9015A-15-54 (S.N. —590067). . . . . . . . . . . . . . . . . . 9015A-20-94
Transmission Control Unit Circuit Theory Engine Control Unit Temperature Sensors
Of Operation (S.N. —590067) . . . . . . . 9015A-15-56 Test (S.N. —590067). . . . . . . . . . . . . . 9015A-20-96
Transmission Modes Of Operation— Engine Control Unit Speed Sensors Test
Manual And Automatic (S.N. — (S.N. —590067). . . . . . . . . . . . . . . . . . 9015A-20-97
590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-15-58 Engine Control Unit Pressure Sensors and
Transmission Functions Set At Monitor Solenoids Test (S.N. —590067) . . . . . 9015A-20-98
Display Unit (S.N. —590067) . . . . . . . . 9015A-15-59 Throttle Position Sensor Adjustment (S.N. —
Transmission Shift Ranges In Automatic 590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-99
Mode (S.N. —590067) . . . . . . . . . . . . . 9015A-15-62 Boom Height Kickout Adjustment (S.N. —
Transmission Control Unit Response To 590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-101
Malfunctions (S.N. —590067) . . . . . . . 9015A-15-65 Return-To-Carry Kickout Adjustment (S.N. —
9015A Park Brake Circuit Theory Of Operation (S.N. 590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-101
—590067) . . . . . . . . . . . . . . . . . . . . . . 9015A-15-67 Return-To-Dig Adjustment (S.N. —
Pilot Enable And Boom Down Circuit 590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-102
Theory Of Operation (S.N. — Continuity Check For Sensors With Two
590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-15-71 Wires (S.N. —590067). . . . . . . . . . . . .9015A-20-104
Return-to-Carry, Boom Height Kickout and Continuity Check For Sensors With Three
Return-to-Dig Circuit Theory Of Operation (S.N. — Wires (S.N. —590067). . . . . . . . . . . . .9015A-20-105
590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-15-73 Replace METRI-PACK™ Connectors (S.N. —
Secondary Steering Circuit Theory Of 590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-106
Operation (S.N. —590067) . . . . . . . . . 9015A-15-75 Replace DEUTSCH™ Connectors (S.N. —
Engine Control Unit Circuit Theory Of 590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-107
Operation (S.N. —590067) . . . . . . . . . 9015A-15-77 Install DEUTSCH™ Contact (S.N. —
590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-108
Group 20—References Replace WEATHER PACK™ Connectors
Alternators And Starting Motors—Use CTM77 (S.N. —590067). . . . . . . . . . . . . . . . . .9015A-20-109
(S.N. —590067). . . . . . . . . . . . . . . . . . . 9015A-20-1 Install WEATHER PACK™ Contact (S.N.
Diagnostic Trouble Codes Quick —590067) . . . . . . . . . . . . . . . . . . . . . .9015A-20-110
Reference List (S.N. —590067) . . . . . . . 9015A-20-2 Remove And Install Transmission Control
Transmission Diagnostic Trouble Codes (S.N. Valve Connector Body (S.N. —
—590067) . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-5 590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-111
Engine Related Diagnostic Trouble Codes Install Transmission Control Valve
(S.N. —590067). . . . . . . . . . . . . . . . . . 9015A-20-42 Connector Contact (S.N. —590067). . .9015A-20-112
Engine Diagnostic Trouble Codes (S.N. — Crimper Tool For Transmission Control
590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-50 Unit Connector—Operation (S.N. —
Steering and Brake Diagnostic Trouble 590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-114
Codes (S.N. —590067) . . . . . . . . . . . . 9015A-20-60 Crimper Tool For Transmission Control Unit
Electrical System Diagnostic Trouble Codes Connector—Remove And Install Die Set (S.N. —
(S.N. —590067). . . . . . . . . . . . . . . . . . 9015A-20-62 590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-115
Hydraulic System Diagnostic Trouble Codes Crimper Tool For Transmission Control Unit
(S.N. —590067). . . . . . . . . . . . . . . . . . 9015A-20-74 Connector—Contact Support Adjustment (S.N. —
Electrical Component Specifications (S.N. — 590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-117
590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-81 Crimper Tool For Transmission Control
Check Controller (S.N. —590067) . . . . . . 9015A-20-87 Unit Connector—Crimping Procedure (S.N. —
Check Battery Electrolyte Level And 590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-118
Terminals (S.N. —590067) . . . . . . . . . 9015A-20-88 Crimper Tool For Transmission Control Unit
Procedure For Testing Batteries (S.N. — Connector—Crimp Height Inspection (S.N. —
590067) . . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-91 590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-120
Transmission Control Valve Solenoid Check
(S.N. —590067). . . . . . . . . . . . . . . . . . 9015A-20-93 Continued on next page

092005
PN=2
Contents
Page
Crimper Tool For Transmission Control Unit

Connector—Crimp Height Adjustment (S.N. —
590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-121
Replace Transmission Control Unit
Connector Terminals (S.N. —
590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-122
Replace Chassis Control Unit Connector
Terminals (S.N. —590067) . . . . . . . . .9015A-20-123
Reprogram Monitor Display Unit (S.N. —
590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-125
Install CINCH™ Contact (S.N. —
590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-126
Remove Connector Body From Blade
Terminals (S.N. —590067) . . . . . . . . .9015A-20-127 9015A
Fuse Block Terminal Remove and Install
(S.N. —590067). . . . . . . . . . . . . . . . . .9015A-20-127
Pressure Switches Remove and Install (S.N.
—590067) . . . . . . . . . . . . . . . . . . . . . .9015A-20-128
Boom Down, Differential Lock, and Pilot
Enable Solenoid Valve Remove And Install (S.N. —
590067) . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-129

092005
PN=3
Contents
9015A

092005
PN=4
Group 05
System Information
9015A
05
1
TM2075 (03MAR05) 9015A-05-1 644J and 724J Loader

092005
PN=69
System Information
Electrical Diagram Information (S.N. —590067)
9015A
05
2
–UN–29FEB00
T128818
Continued on next page CED,TX17984,455 –19–07MAY01–1/6

092005
PN=70
System Information
1—Continuity Chart 4—Wire Identification 7—Section Number 10—Component Schematic

2—Power Wires 5—Ground Wires 8—Component Name Symbol
3—Routing Location 6—Circuit Name 9—Component Identification
Information Number
NOTE: All System Functional Schematics, Circuit Each electrical component is shown by a schematic
Schematics, and Wiring Diagrams are shown symbol (10), the component name (8), and a
with key switch in the OFF position. component identification number (9). A component
identification number and name will remain the same
System Functional Schematic Diagram throughout the Operation and Test Technical Manual.
This will allow for easy cross-referencing of all
The System Functional Schematic is made up of electrical drawings (Schematics, Wiring Diagrams, and
sections which contain one or more Subsystem Component Location). A continuity chart (1) is included
Functional Schematics laid out side by side in a logical for each multi-terminal switch.
sequence of related functions. Each subsystem is a
major group of components like starting components or Routing location information (3) is presented to let the
charging components. Each section of the System reader know when a wire is connected to a component 9015A
Functional Schematic is assigned a number (7) and a in another section. TO and FROM statements identify 05
name (6) that reflects a group of components. The when power is going “To” or coming “From” a 3
System Functional Schematic is formatted with power component in a different location. The section and
supply wires (2) shown across the top of the drawing component number are given in parenthesis at the
and ground wires (5) across the bottom. The bottom of the statement. In the example, power is
schematic contains no harness or connector going TO component F15 Horn Fuse, in section SE15.
information.

092005
PN=71
System Information
9015A
05
4
–UN–29FEB00
T128819

092005
PN=72
System Information
1—Harness Connector Pin 3—Component Identification 6—Component Connector 9—Component Identification

Letter or Number Number 7—Component Connector Pin Number Wire is Routed TO
2—Harness Connector Number 4—Wire Color or Number Letter or Number 10—Wire Color or Number
Identification 5—Component Identification 8—Wiring Harness
Number Wire is Routed TO
Wiring Diagram—If Provided identified by color or number (10). Component

identification number (9) indicates destination of each
Each harness on the machine is drawn showing wire.
components, connectors, and wires. Harnesses are
identified by a “W” component identification number Component Location Diagram
and description (W6 ENGINE HARNESS, Etc.).
The Component Location Diagram is a pictorial view
Each component is represented by a schematic by harness showing location of all electrical
symbol and is identified by a component identification components, connectors, harness main ground
number and name (3). Components with integral locations and harness band and clamp location. Each
connectors (6) have pin number/letters indicated (7). component will be identified by the same identification 9015A
Wires from harness to components are identified by letter/number and description used in the System 05
color or number designation (4). Component Functional Schematic Diagram. 5
identification number (5) indicates the component a
wire is routed TO. Connector End View Diagram—If Provided
Main harness connectors (2) are identified by a “X” The Connector End View Diagram is a pictorial end
component identification number and description (X28 view of the component connectors showing the
CAB TO ENGINE BULKHEAD CONNECTOR, Etc.). number of pins in the connector and the wire color and
Harness connector description indicates which identifier of the wire in every connector. Each
harnesses connect together. Connector pin letters or component will be identified by the same identification
numbers (1) are indicated as they are marked on the letter/number and description used in the System
connector. Wires attached to each connector pin are Functional Schematic Diagram.

092005
PN=73
System Information
T143000 –UN–21JUN01

092005
PN=74
9015A-05-6 - A 9015A-05-6 - B 9015A-05-6 - C
9015A-05-6 - A
T143000 –UN–21JUN01
TM2075 (03MAR05)
9015A-05-6 - B
System Information
9015A-05-6 644J and 724J Loader

092005
PN=74
9015A-05-6 - C
9015A-05-6 - Blank
System Information
1—Battery 25—Sensor with Normally 47—Variable Resistor 63—Momentary Switch

2—Wire Splice Open Switch 48—Manually Adjusted Normally Open
3—Fuse 26—Speed Sensor Variable Resistor 64—Momentary Switch
4—Circuit Breaker 27—Rotary Sensor 49—Multi-Pin Connector Normally Closed
5—Fusible Link 28—Single Element Bulb 50—Single Pin Connector 65—Toggle Switch Normally
6—Power Outlet 29—Dual Element Bulb 51—Connector Open
7—Alternator 30—Solenoid Operated 52—4 Pin Relay 66—Toggle Switch Normally
8—Air Conditioner Hydraulic Valve With 53—5 Pin Relay Closed
Compressor Suppression Diode 54—5 Pin Relay With Internal 67—2 Way Toggle Switch
9—Compressor 31—Solenoid Normally Open Suppression Diode Normally Open
10—Liquid Pump 32—Solenoid Normally Closed 55—5 Pin Relay With Internal 68—2 Way Toggle Switch
11—Antenna 33—Starter Motor Suppression Resistor Normally Closed
12—Diode 34—Starter Motor 56—Key Switch 69—Manual Switch Operation
13—Zener Diode 35—DC Motor 57—Temperature Switch 70—Push Switch Operation
14—Capacitor 36—DC Stepping Motor Normally Open 71—Pull Switch Operation
15—Magnet 37—Wiper Motor 58—Temperature Switch 72—Turn Switch Operation
16—Flasher 38—Blower Motor Normally Closed 73—Toggle Switch Operation
17—Buzzer 39—Servo Motor 59—Pressure Switch Normally 74—Pedal Switch Operation
18—Horn 40—Speedometer Open 75—Key Switch Operation
19—Alarm 41—Tachometer 60—Pressure Switch Normally 76—Detent Switch Operation 9015A
20—Clock 42—Temperature Gauge Closed 77—Temperature Sensor 05
21—Internal Ground 43—Liquid Level Gauge 61—Liquid Level Switch 78—Solar Sensor 7
22—Single Point Ground 44—Gauge Normally Open 79—Pressure Sensor
23—External Ground 45—Hourmeter 62—Liquid Level Switch 80—Liquid Level Sensor
24—Sensor 46—Resistor Normally Closed
Electrical Schematic Symbols
CED,TX17984,455 –19–07MAY01–6/6

092005
PN=75
System Information
9015A
05
8

092005
PN=76
Group 10
System Diagrams
Fuse and Relay Specifications (S.N. —590067)
K25 K27 K17 Rear Wiper K13

Drive Light Hi-Beam Light Return to Park Not Return to Dig
Relay Relay Relay Used Relay
AT162863 AT162863 AT162863 AT162863
K23 Left K28 K18 Rear wiper K15 Front Wiper K19 K22
Not Signal/Flasher Brake Light Intermittent Return to Park Main Blower
Used Horn Relay
Relay Relay Relay Relay Relay AT162863
AT206685 AT162863 AT162863 AT162863 AT162863
K24 Right K32 K16 Front Wiper
Not Signal/Flasher Detent Enable Not Intermittent Not Not
Used Relay Relay Used Relay Used Used
AT206685 AT162863 AT162863
Rear Wiper Motor Cab Work Light Pressurizer Engine Controller Power for BHKO, RTD,
10 AMP Fuse Motor Switched RTC Switch
F18 57M 7121
F29 10 AMP CB
T103463
F20 7.5 AMP Fuse F5 7.5 AMP FUSE 5 AMP Fuse F15
P33 (ACC) P45 (ACC) A19 99M 7064 (ACC) P08 99M 7065 (IGN) P11 57M 7125 (IGN)
K31 Trans Controller CCU 12V
9015A
Not Neutral Start
Ride Control Front Wiper Motor Unswitched Not
F17 10 AMP Fuse Used
Circuit
F3 5 AMP F12 Switched
5 AMP Fuse 5 AMP Fuse F9 10
Fuse
Relay P34 57M 7121 (ACC) P01 57M 7125 (ST) P24 57M 7125 (IGN) P31
57M 7125
(12V BATT) Used 1
AT162863 Ride
Drive & Hi-Beam Light Pilot Enable
Spare
Horns Ignition
F30 7.5 Control
AMP Fuse F25 10 AMP CB F21 7.5 AMP Fuse F16 7.5 AMP Fuse 5 AMP Fuse F34
T103463 99M 7064 99M 7064 57M 7125 (IGN)
J01 99M 7064 (ACC) P40 (BATT) P36 (ACC) P28 (IGN) P47
Power for Pressure Turn Signal/Flasher Spare Blower Motor Monitor Display
Switches Light Accessory 25 AMP Fuse Switched
F10 5 AMP Fuse F22 7.5 AMP Fuse F33 5 AMP Fuse F19 99M 7069 5 AMP Fuse F7
P32 57M 7125 (ACC) P37 99M 7064 (BATT) P49 57M 7125 (ACC) P10 (BATT) P05 57M 7125 (IGN)
Brake Light Seat Adjust, Dome Light, Boom CCU 28 V

Tail & Marker Light Lighter Down & Radio
Switched
F24 7.5 AMP Fuse F27 7.5 Amp Fuse F32 10 AMP Fuse F28 Unswitched
7.5 AMP Fuse 7.5 AMP Fuse F11
99M 7064 (ACC) 99M 7064 (BATT)
P39 P44 P48 57M 7121 (ACC) P14 99M 7064 (BATT) P25 99M 7064 (IGN)
K30 Ride K21 Secondary
Control Boom Diff Lock, Spare Rotary Beacon Converter Park Brake, Steering
Solenoid F14 Pin5Disc Solenoid
AMP Fuse
F35 15 AMP Fuse F26 10 AMP Fuse F31 15Unswitched
AMP Fuse
Back-up Alarm
5 AMP Fuse
F13 (Relay Coil)
99M 7065 57M 7121
Relay P42 57M 7125 (ACC) P35 (BATT) P41 (ACC) P16 99M 7065 (BATT) P26 57M 7125 (IGN) Relay
AT162863 Power for Rocker Engine Controller Alternator Monitor & Trans Controller Start Aid,
AT162863
F23 Switches F6 Unswitched F1 Excitation
F4 Unswitched Converter & Sec. Strg F2
5 AMP Fuse 10 AMP Fuse 7.5 AMP Fuse 5 AMP Fuse 10 AMP Fuse
P27 57M 7125 (ACC) P06 57M 7121 (BATT) J07 99M 7064 (IGN) P02 57M 7125 (BATT) P04 57M 7121 (IGN)
K6 K1 K5 K10 K4
–19–24OCT02
Accessory Neutral Start Accesory Back-Up Ignition
Relay #2 Relay Relay #1 Relay Relay
AT162863 AT162863 AT162863 AT162863 AT162863
T159002
T159002
IMPORTANT: Install fuse with correct amperage The fuse and relay block is located in the load center
rating to prevent electrical system harness. See Load Center Harness (W3) Component
damage from overload. Location (S.N. —590067). (Group 9015-10.)
CED,TX17864,31 –19–29MAR99–1/1

092005
PN=77
System Diagrams
System Functional Schematic Section Legend (S.N. —590067)
NOTE: SE1—Battery, Ignition Power Circuit (24 V • SE18—Chassis Control Unit Circuit
System) • SE19—Chassis Control Unit Circuit
• SE20—Chassis Control Unit Circuit
SE1 indicates section number of System • SE21—Chassis Control Unit Circuit
Functional Schematic where circuit is located. • SE22—Transmission Control Unit Input Circuits
• SE23—Transmission Control Unit Input Circuits
Battery, Ignition Power Circuit (24 V System) • SE24—Transmission Control Unit Input Circuits
indicates circuit name. • SE25—Pilot Enable and Boom Down Circuit
• SE26—Return-to-Carry Circuit
• SE1—Battery, Ignition Power Circuit (24 V System) • SE27—Boom Height Kickout and Return-to-Dig
• SE2—Alternator and Engine Air Heater Circuits Circuit
• SE3—Starting Circuit • SE28—Differential Lock, Pin Disconnect and Axle
• SE4—Start Aid Circuit Disconnect Circuit
• SE5—Ignition Power Circuit • SE29—Front Wiper Circuit
9015A
10 • SE6—Ignition Power Circuit • SE30—Rear Wiper Circuit
2 • SE7—Accessory Power Circuit • SE31—Heater/Pressurizer Circuit
• SE8—Accessory Power Circuit • SE32—Air Conditioning Circuit
• SE9—Accessory Power Circuit • SE33—Secondary Steering and Horn Circuit
• SE10—Ride Control Circuit • SE34—Flasher and Turn Circuit
• SE11—Ride Control Circuit • SE35—Tail/Marker Light Circuit
• SE12—Electric Adjust Seat, Lighter and Spare • SE36—Drive Light and Rotary Beacon Circuit
Circuits • SE37—Brake Light and Dome Light Circuit
• SE13—Monitor Display Unit Circuit • SE38—Cab Work Light Circuit
• SE14—Monitor Display Unit Circuit • SE39—Converter and Radio Circuits
• SE15—Monitor Display Unit Circuit • SE40—Engine Controller Circuit
• SE16—Chassis Control Unit Circuit • SE41—Engine Controller Circuit
• SE17—Chassis Control Unit Circuit • SE42—Engine Controller Circuit
CED,TX17864,33 –19–31MAR98–1/1

092005
PN=78
System Diagrams
Functional Schematic And Component Location Legend (S.N. —590067)
NOTE: A2—Chassis Control Unit (SE18, SE19, W3) • B25—Steering System Pressure Switch (SE21,
W17)
A2 indicates component identification number. • B27—Service Brake Pressure Switch Accumulator
Charge (SE21, W3)
Chassis Control Unit indicates component • B28—Torque Converter Input Speed Sensor (Engine
name. Speed) (SE22, W10)
• B29—Torque Converter Output Speed Sensor
SE18, SE19 indicates section numbers of (SE22, W10)
system functional schematic where component • B30—Internal Clutch Speed Sensor (SE22, W10)
is located. • B31—Transmission Output Shaft Speed Sensor
(SE22, W10)
W3 is the identification number of the • B32—Transmission Oil Temperature Sensor (SE24,
component location and harness connector W10)
(with wire and pin location) drawings for the • B33—Clutch Cut-Off Sensor (SE24, W3)
9015A
component. This would indicate that the • B34—Park Brake Pressure Switch (SE24, W2) 10
Chassis Control Unit is connected to W3 Load • B35—Freeze Control Switch (SE32, W20) 3
Center Harness. • B36—A/C System Pressure Switch (SE32, W20)
• B38—Low-Note Horn (SE33,W2)
• A1—Engine Control Unit (SE41, W3) • B39—Hi-Note Horn (SE33, W2)
• A2—Chassis Control Unit (SE18, SE19, W3) • B40—Brake Light Pressure Switch (SE37, W3)
• A3—Transmission Control Unit (SE23, W3) • B41—Bucket Dump Pressure Switch (SE11, W9)
• A4—Pilot Control Unit (SE27, W3) • B42—Left Speaker (SE39, W34)
• A5—Radio (SE39, W34) • B43—Right Speaker (SE39, W34)
• B48—Water In Fuel Sensor (SE40, W6)
• B1—Engine Coolant Temperature Sensor (SE40, • B49—Fuel Rail Pressure Sensor (SE41, W6)
W6)
• B3—Fuel Temperature Sensor (SE40, W6) • E2—Left Front Turn Light (SE34, W2)
• B4—Engine Crank Position Sensor (SE40, W6) • E3—Left Rear Turn Light (SE34, W13)
• B5—Injection Pump Position Sensor (SE41, W6) • E4—Right Front Turn Light (SE34, W2)
• B7—Intake Manifold Air Temperature Sensor (SE40, • E5—Right Rear Turn Light (SE34, W13)
W6) • E6—Left Front Marker Light (SE35, W2)
• B8—Hydraulic System Pressure Sensor (SE16, W5) • E7—Right Front Marker Light (SE35, W2)
• B9—Boom Position Sensor (SE17, W2) • E8—Left Break Light (SE35, W13)
• B14—Throttle Position Sensor (SE16, W3) • E9—Right Brake Light (SE35, W13)
• B15—Hydraulic Oil Temperature Sensor (SE19, W5) • E10—License Plate Light (SE35, W15)
• B17—Fuel Level Sender (SE19, W5) • E11—Left Front Drive Light (SE36, W2)
• B19—Engine Air Filter Restriction Switch (SE20, • E12—Right Front Drive Light (SE36, W2)
W6) • E15—Rotary Beacon Light (SE36, W19)
• B20—Transmission Oil Filter Restriction Switch • E18—Dome Light (SE37, W19)
(SE20, W10) • E20—Left Front Work Light (SE38, W19)
• B21—Hydraulic Oil Filter Restriction Switch (SE20, • E21—Right Front Work Light (SE38, W19)
W5) • E22—Left Rear Work Light (SE38, W19)
• B22—Return-to-Dig Switch (SE27, W8) • E23—Right Rear Work Light (SE38, W19)
• B23—Engine Oil Pressure Sensor (SE21, W6) • E25—Engine Air Heater (SE2, W7)
Continued on next page TX17994,0000332 –19–22JUL02–1/5

092005
PN=79
System Diagrams
• F1—Alternator Excitation Fuse (SE2, W3) • G2—Emergency Starting Terminal (SE1, W6)
• F2—Start Aid, Converter and Secondary Steering • G3—55 Amp Bosch Alternator (SE2, W6)
Fuse (SE4, W3) • G4—80 Amp Bosch Alternator (SE2, W6)
• F3—Neutral Start Fuse (SE3, W3) • G5—12 V Power Plug (SE39, W21)
• F4—Monitor and Transmission Controller, • G6—24 V to 12 V Voltage Converter (SE39, W21)
Unswitched Fuse (SE14, W3) • G7—24 V to 12 V Voltage Converter (Radio Only)
• F5—Engine Controller Switched Fuse (SE42, W3) (SE39, W34)
• F6—Engine Controller Unswitched Fuse (SE42)
• F7—Monitor, Switched Power Fuse (SE14, W3) • H1—Monitor Alarm (SE13, W4)
• F9—Chassis Control Unit Unswitched Fuse (SE20, • H2—Monitor Display Unit (SE14, W4)
W3) • H3—Back Up Alarm (SE22, W13)
• F10—Steering and Service Brake Pressure Switch
Fuse (SE21, W3) • K1—Neutral Start Circuit Relay (SE3, W3)
• F11—Chassis Control Unit Switched Power Fuse • K3—Start Relay (SE3, W3)
(SE21, W3) • K4—Ignition Power Relay (SE5, W3)
• F12—Transmission Controller Switched Fuse (SE22, • K5—Accessory Power Relay #1 (SE7, W3)
9015A
10 W3) • K6—Accessory Power Relay #2 (SE8, W3)
4 • F13—Park Brake and Back-Up Alarm Fuse (SE22, • K10—Back Up Alarm Relay (SE22, W3)
W3) • K13—Return-to-Dig Relay (SE27, W3)
• F14—Differential Lock and Pin Disconnect Fuse • K15—Front Wiper (Return to Park) Relay (SE29,
(SE28, W3) W3)
• F15—BHKO, RTC, and RTD Fuse (SE26, W3) • K16—Front Intermittent Wiper Relay (SE29, W3)
• F16—Pilot Enable Fuse (SE25, W3) • K17—Rear Wiper (Return to Park) Relay (SE30,
• F17—Front Wiper Fuse (SE29, W3) W3)
• F18—Rear Wiper Fuse (SE30, W3) • K18—Rear Intermittent Wiper Relay (SE30, W3)
• F19—Blower Motor Fuse (SE31, W3) • K19—Blower and Pressurizer Motor Relay (SE31,
• F20—Pressurizer Motor Fuse (SE31, W3) W3)
• F21—Horn Fuse (SE33, W3) • K21—Secondary Steering Relay (SE33, W3)
• F22—Turn Light Fuse (SE34, W3) • K22—Horn Relay (SE33, W3)
• F23—Rocker Switches and Radio Fuse (SE16, W3) • K23—Left Flasher Relay (SE34, W3)
• F24—Tail/Marker Light Fuse (SE35, W3) • K24—Right Flasher Relay (SE34, W3)
• F25—Drive Light Circuit Breaker (SE36, W3) • K25—Drive Light Relay (SE35, W3)
• F26—Rotary Beacon Fuse (SE36, W3) • K28—Brake Light Relay (SE37, W3)
• F27—Brake Light Fuse (SE37, W3) • K30—Ride Control Boom Relay (SE10, W3)
• F28—Unswitched Boom Down, Radio and Dome • K31—Ride Control (On/Off) Relay (SE11, W3)
Light Fuse (SE37, W3) • K32—Detent Enable and Pilot Enable Relay (SE26,
• F29—Cab Work Light Circuit Breaker (SE38, W3) W3)
• F30—Ride Control Fuse (SE10, W3) • K33—Engine Air Heater Coil Relay (SE2, W3)
• F31—Converter, Unswitched Fuse (SE39, W3) • K34—Engine Air Heater Relay (SE2, W7)
• F32—Air Seat Adjust Fuse (SE12, W3)
• F33—Spare Accessory Fuse (SE12, W3) • M1—Starter Motor (SE1, W3, W6, W7, W23, W24)
• F34—Spare Ignition Fuse (SE12, W3) • M2—Front Washer Pump (SE29, W5)
• F35—Spare Battery Fuse (SE12, W3) • M3—Front Wiper Motor (SE29, W4)
• F36—Engine Air Heater Fuse (SE2, W7) • M4—Rear Washer Pump (SE30, W5)
• M5—Rear Wiper Motor (SE30, W19)
• G1—Batteries (SE1, W24) • M6—Blower Motor (SE31, W20)

092005
PN=80
System Diagrams
• M7—Pressurizer Blower Motor (SE31, W20) • V8—Differential Lock Diode (SE28, W5)
• M8—Secondary Steering Pump Motor (SE33, W23) • V9—Pilot Enable/Boom Down Diode (SE25, W5)
• M9—Electric Air Adjust Seat Motor (SE12, W36) • V11—A/C Clutch Diode 1 A (SE32, W6)
• R1—CAN Termination Node (SE13, W3) • W1—Antenna (SE39, W34)

• R2—CAN Termination Node (SE15, W4) • W2—Loader Frame Harness
• R3—Blower Speed Resistor (SE31, W20) • W3—Load Center Harness
• R5—Spin Control Resistor (SE16, W14) • W4—Front Console Harness
• W5—Engine Frame Harness
• S1—Key Switch (SE1, W4) • W6—Engine Harness
• S2—Manual Battery Disconnect Switch (SE1, W24) • W7—Engine Air Heater Harness
• S3—Start Aid Switch (SE4, W4) • W8—Return-to-Dig Harness
• S5—Spin Control Switch (SE16, W3) • W9—Ride Control Harness
• S6—Automatic Transmission Switch (SE22, W3) • W10—Transmission Harness
• S7—Quick Shift Switch (SE22, W3) • W13—Rear Frame Harness
• S8—Park Brake Release Switch (SE22, W4) • W14—Spin Control Mode Harness
9015A
• S10—Shifter Switch (SE23, W4) • W15—License Plate Light Harness 10
• S11—Clutch Cut-Off Enable Switch (SE24, W3) • W16—Pin and Axle Disconnect Harness 5
• S12—Pin Disconnect Switch (SE28, W3) • W17—Secondary Steering Switch Harness
• S13—Differential Lock (Foot) Switch (SE28, W3) • W19—Cab Work Light Harness
• S15—Return-to-Carry Switch (SE26, W3) • W20—Blower/AC Harness
• S16—Boom Height Kickout Switch (SE26, W3) • W21—Converter and Power Plug Harness
• S18—Pilot Enable/Boom Down Switch (SE25, W3) • W23—Secondary Steering Pump Motor Harness
• S19—Front Wiper Switch (SE29, W3) • W24—Battery Harness (4 Battery Cables)
• S20—Rear Wiper Switch (SE30, W3) • W27—Engine Frame Ground (W6)
• S21—Blower Speed Switch (SE31, W3) • W29—Right Front Cab Leg Ground (W3)
• S22—A/C (On/Off) Switch (SE32, W3) • W34—Radio Harness
• S23—Horn Switch (SE33, W4) • W36—Electric Air Adjust Seat Harness
• S24—4-Way Flasher Switch (SE34, W3) • W37—CAN Terminator Harness (1 for Front Console
• S25—Turn Switch (SE14, W4) Harness, 1 for Load Center Harness)
• S26—Drive and Tail/Marker Light Switch (SE35, W3)
• S27—Rotary Beacon Switch (SE36, W3) • X1—Engine Frame Harness to Rear Frame Harness
• S28—Dome Light Switch (SE37, W19) Connector (W5, W13)
• S29—Door Light Switch (SE37, W19) • X2—Engine Frame Harness to Rear Frame Harness
• S30—Cab Work Light Switch (SE38, W3) Connector (W5, W13)
• S31—Ride Control Switch (SE10, W3) • X3—Loader Frame Harness to Pin Disconnect
• S32—Air Seat Adjustment Switch (SE12, W3) Harness Connector (W2, W16)
• S33—Spin Control Mode Switch (SE16, W14) • X4—Engine Frame Harness to Load Center Harness
• S35—Axle Disconnect Switch (SE28, W3) Connector (W3, W5)
• S41—Reverse Fan Switch (SE17, W3) • X5—Load Center Harness to Engine Harness
Connector (W3, W6)
• V1—Starter Coil Suppression Diode 5 A (SE1, W3) • X6—Load Center Harness to Transmission Harness
• V2—Alternator Excitation Diode 5 A (SE2, W6) Connector (W3, W10)
• V3—Start Aid Diode 1 A (SE4, W5) • X7—Load Center to Loader Frame Harness
• V5—Start Relay Coil Suppression Diode 1 A (SE3, Connector (W2, W3)
W3)

092005
PN=81
System Diagrams
• X8—Load Center to Loader Frame Harness • X37—Spare (IGN) Connector (W3)

Connector (W2, W3) • X38—Transmission Control Unit Connector (W3)
• X9—Load Center to Loader Frame Harness • X39—Monitor Display Unit Connector (Programming)
Connector (W2, W3) (Factory Only) (W4)
• X10—Loader Frame Harness to Ride Control • X41—Transmission Control Valve Connector (W10)
Harness Connector (W2, W9) • X42—Engine Harness to Engine Air Heater Harness
• X11—Return-to-Dig Harness to Loader Frame Connector (W6, W7)
Harness Connector (W2, W8) • X43—Engine Harness to Secondary Steering Pump
• X12—Load Center Harness to Spin Control Mode Motor Harness Connector (W6, W23)
Harness Connector (W3, W14) • X44—Engine Frame Harness to Battery Harness
• X13—Front Console Harness to Load Center Connector (W5, W24)
Harness Connector (W3, W4) • X45—Converter and Power Plug Harness to 12 V
• X14—A/C High Pressure Switch Jumper (SE32, Accessory Connector (W21)
W20) • X47—Load Center Harness to Radio Harness
• X15—Fuel Injector Connector (W6) Connector (W3, W34)
• X17—Cab Work Light Harness to Load Center • X48—Load Center Harness to Air Adjust Seat
9015A
10 Harness Connector (W3, W19) Harness Connector (W3, W36)
6 • X18—Cab Work Light Harness to Load Center • X49—Return-to-Carry Without Switch Connection
Harness Connector (W3, W19) (W3)
• X19—Blower and AC Harness to Load Center • X50—Engine Control Unit Diagnostic Connector
• X20—Blower and AC Harness to Load Center • X51—Engine Control Unit Connector (Engine Side)
Harness Connector (W3, W20) (Part A) (W3)
• X21—Blower and AC Harness to Load Center • X52—Engine Control Unit Connector (Engine Side)
Harness Connector (W3, W20) (Part B) (W3)
• X24—License Plate Harness to Rear Frame • X53—TCU Diagnostic And Programming Connector
Harness Connector (W13, W15) (SE24, W3)
• X25—Loader Frame Harness to Load Center • X54—SERVICE ADVISOR™ System Connector
• X26—Secondary Steering Switch Harness to Load • X55—Engine Air Heater Option Relay Connector
Center Harness Connector (W3, W17) (W5)
• X27—Converter and Power Plug Harness to Load • X56—Pilot Controller Connector (W3)
Center Harness Connector (W3, W21)
• X28—CAN Terminator Harness to Load Center • Y1—Transmission Control Solenoid (SE23, W10)
Harness and to Front Console Harness Connector • Y2—Transmission Control Solenoid (SE23, W10)
(W3, W4, W37) • Y3—Transmission Control Solenoid (SE23, W10)
• X30—Loader Frame Harness to Axle Disconnect • Y4—Transmission Control Solenoid (SE23, W10)
Harness Connector (W2, W16) • Y5—Transmission Control Solenoid (SE23, W10)
• X32—Chassis Controller Connector (Programming) • Y6—Transmission Control Solenoid (SE23, W10)
(Factory Only) (W3) • Y7—Start Aid Solenoid (SE4, W13)
• X33—Chassis Controller Connector (30 pin) (W3) • Y8—Injection Pump Control Solenoid 1 (SE42, W6)
• X34—Chassis Controller Connector (60 pin) (W3) • Y9—Injection Pump Control Solenoid 2 (SE42, W6)
• X35—Spare (BATT) Connector (W3) • Y13—Differential Lock Solenoid (SE28, W5)
• X36—Spare (ACC) Connector (W3) • Y14—Pilot Enable Solenoid (SE25, W5)
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page TX17994,0000332 –19–22JUL02–4/5

092005
PN=82
System Diagrams
• Y15—Boom Down Solenoid (SE25, W5) • Y24—Fuel Injector Solenoid 4 (SE42, W6)
• Y16—A/C Compressor Clutch Solenoid (SE32, W6) • Y25—Fuel Injector Solenoid 5 (SE42, W6)
• Y17—Ride Control Boom Solenoid (SE11, W9) • Y26—Fuel Injector Solenoid 6 (SE42, W6)
• Y18—Ride Control (On/Off) Solenoid (SE11, W9) • Y31—Axle Disconnect Solenoid (SE28, W16)
• Y19—Park Brake Release Solenoid (SE24, W2) • Y34—Ride Control (On/Off) Solenoid (SE11, W9)
• Y20—Pin Disconnect Solenoid (SE28, W16) • Y37—Variable Speed Fan Motor Solenoid (SE18,
• Y21—Fuel Injector Solenoid 1 (SE42, W6) W5)
• Y22—Fuel Injector Solenoid 2 (SE42, W6) • Y38—Reverse Fan Solenoid (SE17, W5)
• Y23—Fuel Injector Solenoid 3 (SE42, W6)
TX17994,0000332 –19–22JUL02–5/5
9015A
10
7

092005
PN=83
System Diagrams
System Functional Schematic (S.N. —590067)

T156365 –19–22OCT02
TX17994,000032C –19–17JUN02–1/14

092005
PN=84
9015A-10-8 - A 9015A-10-8 - B 9015A-10-8 - C
9015A-10-8 - A
System Functiona
T156365 –19–22OCT02
TM2075 (03MAR05)
9015A-10-8 - B
System Diagrams
onal Schematic (S.N. —590067)
TX17994,000032C –19–17JUN02–1/14
9015A-10-8 644J and 724J Loader

092005
PN=84
9015A-10-8 - C
9015A-10-8 - Blank
System Diagrams
T156351 –19–24SEP02
TX17994,000032C –19–17JUN02–2/14

092005
PN=85
9015A-10-9 - A 9015A-10-9 - B 9015A-10-9 - C
System Diagrams
T156351 –19–24SEP02
TX17994,000032C –19–
TM2075 (03MAR05) 9015A-10-9 644J and 72
9015A-10-9 - A
–19–17JUN02–2/14
nd 724J Loader
092005
PN=85
9015A-10-9 - B
9015A-10-9 - C
9015A-10-9 - Blank
System Diagrams
T156352 –19–24SEP02
TX17994,000032C –19–17JUN02–3/14

092005
PN=86
9015A-10-10 - A 9015A-10-10 - B 9015A-10-10 - C
9015A-10-10 - A
T156352 –19–24SEP02
TM2075 (03MAR05)
9015A-10-10 - B
System Diagrams
TX17994,000032C –19–17JUN02–3/14
9015A-10-10 644J and 724J Loader

092005
PN=86
9015A-10-10 - C
9015A-10-10 - Blank
System Diagrams
T156353 –19–24SEP02
TX17994,000032C –19–17JUN02–4/14

092005
PN=87
9015A-10-11 - A 9015A-10-11 - B 9015A-10-11 - C
System Diagrams
T156353 –19–24SEP02
TX17994,000032C –19–
TM2075 (03MAR05) 9015A-10-11 644J and 72
9015A-10-11 - A
–19–17JUN02–4/14
nd 724J Loader
092005
PN=87
9015A-10-11 - B
9015A-10-11 - C
9015A-10-11 - Blank
System Diagrams
T156354 –19–24SEP02
TX17994,000032C –19–17JUN02–5/14

092005
PN=88
9015A-10-12 - A 9015A-10-12 - B 9015A-10-12 - C
9015A-10-12 - A
T156354 –19–24SEP02
TM2075 (03MAR05)
9015A-10-12 - B
System Diagrams
TX17994,000032C –19–17JUN02–5/14
9015A-10-12 644J and 724J Loader

092005
PN=88
9015A-10-12 - C
9015A-10-12 - Blank
System Diagrams
T156355 –19–24SEP02
TX17994,000032C –19–17JUN02–6/14

092005
PN=89
9015A-10-13 - A 9015A-10-13 - B 9015A-10-13 - C
System Diagrams
T156355 –19–24SEP02
TX17994,000032C –19–
TM2075 (03MAR05) 9015A-10-13 644J and 72
9015A-10-13 - A
–19–17JUN02–6/14
nd 724J Loader
092005
PN=89
9015A-10-13 - B
9015A-10-13 - C
9015A-10-13 - Blank
System Diagrams
T156356 –19–24SEP02
TX17994,000032C –19–17JUN02–7/14

092005
PN=90
9015A-10-14 - A 9015A-10-14 - B 9015A-10-14 - C
9015A-10-14 - A
T156356 –19–24SEP02
TM2075 (03MAR05)
9015A-10-14 - B
System Diagrams
TX17994,000032C –19–17JUN02–7/14
9015A-10-14 644J and 724J Loader

092005
PN=90
9015A-10-14 - C
9015A-10-14 - Blank
System Diagrams
T156357 –19–24SEP02
TX17994,000032C –19–17JUN02–8/14

092005
PN=91
9015A-10-15 - A 9015A-10-15 - B 9015A-10-15 - C
System Diagrams
T156357 –19–24SEP02
TX17994,000032C –19–
TM2075 (03MAR05) 9015A-10-15 644J and 72
9015A-10-15 - A
–19–17JUN02–8/14
nd 724J Loader
092005
PN=91
9015A-10-15 - B
9015A-10-15 - C
9015A-10-15 - Blank
System Diagrams
T161855 –19–03DEC02
TX17994,000032C –19–17JUN02–9/14

092005
PN=92
9015A-10-16 - A 9015A-10-16 - B 9015A-10-16 - C
9015A-10-16 - A
T161855 –19–03DEC02
TM2075 (03MAR05)
9015A-10-16 - B
System Diagrams
TX17994,000032C –19–17JUN02–9/14
9015A-10-16 644J and 724J Loader

092005
PN=92
9015A-10-16 - C
9015A-10-16 - Blank
System Diagrams
T161856 –19–22NOV02
TX17994,000032C –19–17JUN02–10/14

092005
PN=93
9015A-10-17 - A 9015A-10-17 - B 9015A-10-17 - C
System Diagrams
T161856 –19–22NOV02
TX17994,000032C –19–1
TM2075 (03MAR05) 9015A-10-17 644J and 72
9015A-10-17 - A
–19–17JUN02–10/14
nd 724J Loader
092005
PN=93
9015A-10-17 - B
9015A-10-17 - C
9015A-10-17 - Blank
System Diagrams
T156360 –19–24SEP02
TX17994,000032C –19–17JUN02–11/14

092005
PN=94
9015A-10-18 - A 9015A-10-18 - B 9015A-10-18 - C
9015A-10-18 - A
T156360 –19–24SEP02
TM2075 (03MAR05)
9015A-10-18 - B
System Diagrams
TX17994,000032C –19–17JUN02–11/14
9015A-10-18 644J and 724J Loader

092005
PN=94
9015A-10-18 - C
9015A-10-18 - Blank
System Diagrams
T156361 –19–24SEP02
TX17994,000032C –19–17JUN02–12/14

092005
PN=95
9015A-10-19 - A 9015A-10-19 - B 9015A-10-19 - C
System Diagrams
T156361 –19–24SEP02
TX17994,000032C –19–1
TM2075 (03MAR05) 9015A-10-19 644J and 72
9015A-10-19 - A
–19–17JUN02–12/14
nd 724J Loader
092005
PN=95
9015A-10-19 - B
9015A-10-19 - C
9015A-10-19 - Blank
System Diagrams
T156362 –19–16OCT02
TX17994,000032C –19–17JUN02–13/14

092005
PN=96
9015A-10-20 - A 9015A-10-20 - B 9015A-10-20 - C
9015A-10-20 - A
T156362 –19–16OCT02
TM2075 (03MAR05)
9015A-10-20 - B
System Diagrams
TX17994,000032C –19–17JUN02–13/14
9015A-10-20 644J and 724J Loader

092005
PN=96
9015A-10-20 - C
9015A-10-20 - Blank
System Diagrams
T156363 –19–22OCT02
TX17994,000032C –19–17JUN02–14/14

092005
PN=97
9015A-10-21 - A 9015A-10-21 - B 9015A-10-21 - C
System Diagrams
T156363 –19–22OCT02
TX17994,000032C –19–1
TM2075 (03MAR05) 9015A-10-21 644J and 72
9015A-10-21 - A
–19–17JUN02–14/14
nd 724J Loader
092005
PN=97
9015A-10-21 - B
9015A-10-21 - C
9015A-10-21 - Blank
System Diagrams
Loader Frame Harness (W2) Component Location (S.N. —590067)

T155793 –UN–28JUN02
CED,TX17864,35 –19–02JUN00–1/2

092005
PN=98
9015A-10-22 - A 9015A-10-22 - B 9015A-10-22 - C
9015A-10-22 - A
Loader Frame Har
T155793 –UN–28JUN02
TM2075 (03MAR05)
9015A-10-22 - B
System Diagrams
Harness (W2) Component Location (S.N. —590067)
CED,TX17864,35 –19–02JUN00–1/2
9015A-10-22 644J and 724J Loader

092005
PN=98
9015A-10-22 - C
9015A-10-22 - Blank
System Diagrams
B9—Boom Position Sensor E11—Left Front Drive Light X9—Load Center to Loader X11—Return-to-Dig Harness to
B34—Park Brake Pressure E12—Right Front Drive Light Frame Harness Loader Frame Harness
Switch X3—Loader Frame Harness to Connector Connector
B38—Low-Note Horn Pin Disconnect Harness X25—Loader Frame Harness X30—Loader Frame Harness
B39—Hi-Note Horn Connector to Load Center Harness to Axle Disconnect
E2—Left Front Turn Light X7—Load Center to Loader Connector Harness Connector
E4—Right Front Turn Light Frame Harness Connector X10—Loader Frame Harness Y19—Park Brake Release
E6—Left Front Marker Light X8—Load Center to Loader to Ride Control Harness Solenoid
E7—Right Front Marker Light Frame Harness Connector Connector
CED,TX17864,35 –19–02JUN00–2/2
Load Center Harness (W3) Component

Location (S.N. —590067) 9015A
10
23
See Fuse and Relay Specifications (S.N. —590067) for
fuse and relay location. (Group 9015A-10.)
Continued on next page CED,TX17864,37 –19–27SEP02–1/10

092005
PN=99
System Diagrams
T159929 –UN–24OCT02

092005
PN=100
9015A-10-24 - A 9015A-10-24 - B 9015A-10-24 - C
9015A-10-24 - A
T159929 –UN–24OCT02
TM2075 (03MAR05)
9015A-10-24 - B
System Diagrams
9015A-10-24 644J and 724J Loader

092005
PN=100
9015A-10-24 - C
9015A-10-24 - Blank
System Diagrams
A—Fuse and Relay Load X4—Engine Frame X20—Blower and AC X33—Chassis Controller
Center Harness-to-Load Center Harness-to-Load Center Connector (30 pin)
C—Side Console (See Detail Harness Connector Harness Connector X34—Chassis Controller
C) X5—Load Center X21—Blower and AC Connector (60 pin)
A1—Engine Control Unit (ECU) Harness-to-Engine Harness-to-Load Center X35—Spare (BATT) Connector
A2—Chassis Control Unit Harness Connector Harness Connector X36—Spare (ACC) Connector
(CCU) X7—Load Center-to-Loader X25—Load Center X37—Spare (IGN) Connector
A3—Transmission Control Unit Frame Harness Connector Harness-to-Loader X38—Transmision Control Unit
(TCU) X8—Load Center-to-Loader Frame Harness Connector
A4—Pilot Control Unit Frame Harness Connector Connector X51—Engine Control Unit (A1)
B14—Analog Throttle Position X9—Load Center-to-Loader X26—Load Center Connectors
Sensor Frame Harness Connector Harness-to-Secondary X52—Engine Control Unit (A1)
B27—Service Brake X13—Front Console Steering Switch Harness Connectors
Accumulator Charge Harness-to-Load Center Connector X53—TCU Diagnostic and
Pressure Switch Harness Connector X27—Converter and Power Programming Connector
B33—Clutch Cut-Off Sensor X17—Cab Work Light Plug Harness-to-Load X54—Engine Control Unit
B40—Brake Light Pressure Harness-to-Load Center Center Harness Connectors
Switch Harness Connector Connector X55—Engine Control Unit
K3—Start Relay X18—Cab Work Light X28—CAN Terminator Connectors
M1—Starter Motor Harness-to-Load Center Harness-to-Load Center X56—Service ADVISOR 9015A
S7—Quick Shift Switch Harness Connector Harness and to Front Connector 10
V1—Starter Coil Suppression X19—Blower and AC Console Harness 25
Diode Harness-to-Load Center Connector
W29—Right Front Cab Leg Harness Connector X32—Chassis Controller
Ground Connector
(Programming) (Factory
Only)

092005
PN=101
System Diagrams
9015A
10
26
–UN–10OCT02
T159930

092005
PN=102
System Diagrams
1—Temperature Control S18—Pilot Enable/Boom Down S27—Rotary Beacon Switch (If X47—Load Center
S6—Automatic Transmission Switch Equipped) Harness-to-Radio
Switch S20—Rear Wiper Switch S30—Cab Work Light Switch Harness Connector
S11—Clutch Cut-Off Enable S21—Blower Speed Switch S31—Ride Control Switch X48—Load Center
Switch S22—A/C (On/Off) Switch X12—Load Center Harness-to-Electric Air
S12—Pin Disconnect Switch S24—4-Way Flasher Switch Harness-to-Spin Control Seat Adjust Harness
S15—Return-to-Carry (Enable) S26—Drive and Tail/Marker Mode Harness Connector
Switch Light Switch Connector
S16—Boom Height Kickout
Switch
9015A
10
27

092005
PN=103
System Diagrams
T159931 –UN–19OCT02

092005
PN=104
9015A-10-28 - A 9015A-10-28 - B 9015A-10-28 - C
9015A-10-28 - A
T159931 –UN–19OCT02
TM2075 (03MAR05)
9015A-10-28 - B
System Diagrams
9015A-10-28 644J and 724J Loader

092005
PN=104
9015A-10-28 - C
9015A-10-28 - Blank
System Diagrams
9015A
10
29

092005
PN=105
System Diagrams
T159932 –UN–19OCT02

092005
PN=106
9015A-10-30 - A 9015A-10-30 - B
T159932 –UN–1
TM2075 (03
9015A-10-30 - A
System Diagrams
–UN–19OCT02
5 (03MAR05) 9015A-10-30 644J and 724J Loader

092005
PN=106
9015A-10-30 - B
System Diagrams
X4—Engine Frame Harness to X13—Front Console Harness X19—Blower and AC Harness X27—Converter and Power
Load Center Harness to Load Center Harness to Load Center Harness Plug Harness to Load
Connector Connector Connector Center Harness
X5—Load Center Harness to X17—Cab Work Light Harness X20—Blower and AC Harness Connector
Engine Harness to Load Center Harness to Load Center Harness X28—CAN Terminator Harness
Connector Connector Connector to Load Center Harness
X6—Load Center Harness to X18—Cab Work Light Harness X21—Blower and AC Harness and to Front Console
Transmission Harness to Load Center Harness to Load Center Harness Harness Connector
Connector Connector Connector
9015A
10
31

092005
PN=107
System Diagrams
T159933 –UN–10OCT02
Harness Components and Connector Pin Location (A)

092005
PN=108
9015A-10-32 - A 9015A-10-32 - B 9015A-10-32 - C
9015A-10-32 - A
T159933 –UN–10OCT02
TM2075 (03MAR05)
9015A-10-32 - B
System Diagrams
Harness Components and Connector Pin Location (A)
9015A-10-32 644J and 724J Loader

092005
PN=108
9015A-10-32 - C
9015A-10-32 - Blank
System Diagrams
1—Temperature Control S11—Clutch Cut-Off Enable S20—Rear Wiper Switch V5—Start Relay Coil
Switch Switch S21—Blower Speed Switch Suppression Diode
A5—Radio S12—Pin Disconnect Switch S22—A/C (On/Off) Switch X35—Spare (BATT) Connector
B14—Throttle Position Sensor S13—Differential Lock (Foot) S24—4-Way Flasher Switch X36—Spare (ACC) Connector
B27—Service Brake Pressure Switch S26—Drive and Tail/Marker X37—Spare (IGN) Connector
Switch S15—Return-to-Carry Switch Light Switch X48—Load Center Harness to
B33—Clutch Cut-Off Sensor S16—Boom Height Kickout S27—Rotary Beacon Switch Air Adjust Seat Harness
B40—Brake Light Pressure Switch S30—Cab Work Light Switch Connector
Switch S18—Pilot Enable/Boom Down S31—Ride Control Switch X53—TCU Diagnostic And
K3—Start Relay Switch S35—Axle Disconnect Switch Programming Connector
M1—Starter Motor S19—Front Wiper Switch V1—Starter Coil Suppression
S6—Automatic Transmission Diode
Switch
9015A
10
33
CED,TX17864,37 –19–27SEP02–10/10

092005
PN=109
System Diagrams
Front Console Harness (W4) Component Location (S.N. —590067)

T131081 –19–05JUN00
TX,10,111518 –19–26JAN01–1/2

092005
PN=110
9015A-10-34 - A 9015A-10-34 - B
Front Co
T131081 –19–0
TM2075 (03
9015A-10-34 - A
System Diagrams
t Console Harness (W4) Component Location (S.N. —590067)

–19–05JUN00
TX,10,111518 –19–26JAN01–1/2

092005
PN=110
9015A-10-34 - B
System Diagrams
T137515 –19–20JAN01
Harness Connector Pin Location (Rear View Shown)
TX,10,111518 –19–26JAN01–2/2

092005
PN=111
9015A-10-35 - A 9015A-10-35 - B 9015A-10-35 - C
System Diagrams
T137515 –19–20JAN01
Harness Connector Pin Location (Rear View Shown)
TX,10,111518 –19
TM2075 (03MAR05) 9015A-10-35 644J and 72
9015A-10-35 - A
18 –19–26JAN01–2/2
nd 724J Loader
092005
PN=111
9015A-10-35 - B
9015A-10-35 - C
9015A-10-35 - Blank
System Diagrams
Engine Frame Harness (W5) Component Location (S.N. —590067)

T161854 –UN–22NOV02
CED,TX17864,39 –19–02JUN00–1/2

092005
PN=112
9015A-10-36 - A 9015A-10-36 - B 9015A-10-36 - C
9015A-10-36 - A
Engine Frame Har
T161854 –UN–22NOV02
TM2075 (03MAR05)
9015A-10-36 - B
System Diagrams
Harness (W5) Component Location (S.N. —590067)
CED,TX17864,39 –19–02JUN00–1/2
9015A-10-36 644J and 724J Loader

092005
PN=112
9015A-10-36 - C
9015A-10-36 - Blank
System Diagrams
B8—Hydraulic System V3—Start Aid Diode X4—Engine Frame Harness to Y7—Start Aid Solenoid
Pressure Sensor V8—Differential Lock Diode Load Center Harness Y13—Differential Lock
B15—Hydraulic Oil V9—Pilot Enable/Boom Down Connector Solenoid
Temperature Sensor Diode X31—Engine Frame Harness Y14—Pilot Enable Solenoid
B17—Fuel Level Sender W26—Ground to Engine Frame to Sump Tank Harness Y15—Boom Down Solenoid
B21—Hydraulic Oil Filter X1—Engine Frame Harness to Connector
Restriction Switch Rear Frame Harness X44—Engine Frame Harness
M3—Front Washer Pump Connector to Battery (Cables)
M4—Rear Washer Pump X2—Engine Frame Harness to Harness Connector
Rear Frame Harness
Connector
CED,TX17864,39 –19–02JUN00–2/2
9015A
10
37

092005
PN=113
System Diagrams
Engine Harness (W6) Component Location (S.N. —590067)

T157693 –UN–31OCT02
CED,TX17864,41 –19–02JUN00–1/2

092005
PN=114
9015A-10-38 - A 9015A-10-38 - B 9015A-10-38 - C
9015A-10-38 - A
Engine Harness (W
T157693 –UN–31OCT02
TM2075 (03MAR05)
9015A-10-38 - B
System Diagrams
ss (W6) Component Location (S.N. —590067)
CED,TX17864,41 –19–02JUN00–1/2
9015A-10-38 644J and 724J Loader

092005
PN=114
9015A-10-38 - C
9015A-10-38 - Blank
System Diagrams
B1—Engine Coolant B17—Fuel Level Sender V2—Alternator Excitation X55—Engine Air Heater Option
Temperature Sensor B19—Engine Air Filter Diode Relay Connector
B3—Fuel Temperature Sensor Restriction Switch V11—A/C Clutch Diode Y8—Injection Pump Control
B4—Engine Crank Position B23—Engine Oil Pressure X5—Load Center Harness to Solenoid 1
Sensor Sensor Engine Harness Y9—Injection Pump Control
B5—Injection Pump Position B48—Water In Fuel Sensor Connector Solenoid 2
Sensor B49—Fuel Rail Pressure X43—Engine Harness to Y16—A/C Compressor Clutch
B7—Intake Manifold Air Sensor Secondary Steering Solenoid
Temperature Sensor M1—Starter Motor Pump Motor Harness
Connector
CED,TX17864,41 –19–02JUN00–2/2
9015A
10
39

092005
PN=115
System Diagrams
Engine Air Heater Harness (W7) Component Location (S.N. —590067)
9015A
10
40
–19–16FEB98
T113195
Continued on next page CED,TX17864,43 –19–02JUN00–1/2

092005
PN=116
System Diagrams
9015A
10
41
–19–10JAN97
T106074
CED,TX17864,43 –19–02JUN00–2/2

092005
PN=117
System Diagrams
Return-To-Dig Harness (W8) Component Location (S.N. —590067)
9015A
10
42
–19–05JUN00
T131085
CED,TX17864,45 –19–02JUN00–1/1

092005
PN=118
System Diagrams
9015A
10
43

092005
PN=119
System Diagrams
Ride Control Harness (W9) Component Location (S.N. —590067)
9015A
10
44
–UN–23JUL02
T153147

092005
PN=120
System Diagrams
B41—Ride Control Pressure Y17—Ride Control Boom Y18—Ride Control (On/Off) Y34—Ride Control (On/Off)
Switch Solenoid Solenoid Solenoid
X10—Loader Frame Harness
to Ride Control Harness
Connector
CED,TX17864,47 –19–02JUN00–2/2
9015A
10
45

092005
PN=121
System Diagrams
Transmission Harness (W10) Component Location (S.N. —590067)

T159085 –UN–29OCT02
TX,9015,111861 –19–26JAN01–1/2

092005
PN=122
9015A-10-46 - A 9015A-10-46 - B
Transmi
T159085 –UN–2
TM2075 (03
9015A-10-46 - A
System Diagrams
smission Harness (W10) Component Location (S.N. —590067)

–UN–29OCT02
TX,9015,111861 –19–26JAN01–1/2

092005
PN=122
9015A-10-46 - B
System Diagrams
B20—Transmission Oil Filter B31—Transmission Output X41—Transmission Control Y4—Transmission Control

Restriction Switch Shaft Speed Sensor Valve Connector Solenoid
B28—Troque Converter Input B32—Transmission Oil Y1—Transmission Control Y5—Transmission Control
Shaft Sensor (Engine Temperature Sensor Solenoid Solenoid
Speed) X6—Transmission Harness to Y2—Transmission Control Y6—Transmission Control
B29—Torque Converter Output Load Center Harness Solenoid Solenoid
Speed Sensor Connector Y3—Transmission Control
B30—Internal Clutch Speed Solenoid
Sensor
TX,9015,111861 –19–26JAN01–2/2
9015A
10
47

092005
PN=123
System Diagrams
Rear Frame Harness (W13) Component Location (S.N. —590067)
9015A
10
48
–UN–19SEP02
T156827
Continued on next page TX,9015,111863 –19–26JAN01–1/2

092005
PN=124
System Diagrams
E3—Left Rear Turn Light E9—Right Brake Light X1—Engine Frame Harness to X24—License Plate Harness to
E5—Right Rear Turn Light H3—Back-Up Alarm Rear Frame Harness Rear Frame Harness
E8—Left Brake Light Connector Connector
TX,9015,111863 –19–26JAN01–2/2
Spin Control Harness (W14) Component Location (S.N. —590067)
9015A
10
49
–UN–18SEP02
T159084
R5—Spin Control Resistor S5—Spin Control (On/Off) S33—Spin Control Switch X12—Spin Control Harness to
Switch Load Center Harness
Connector
TX17994,0000344 –19–03SEP02–1/1

092005
PN=125
System Diagrams
License Plate Light Harness (W15) Component Location (S.N. —590067)
9015A
10
50
–19–10SEP97
T110557
TX,9015,111866 –19–03SEP97–1/1

092005
PN=126
System Diagrams
9015A
10
51

092005
PN=127
System Diagrams
Pin and Axle Disconnect Harness (W16) Component Location (S.N. —590067)
9015A
10
52
–UN–01OCT02
T159083

092005
PN=128
System Diagrams
X3—Pin Disconnect Harness X30—Axle Disconnect Harness Y20—Pin Disconnect Solenoid Y31—Axle Disconnect
to Loader Frame Harness to Loader Frame Solenoid
Connector Harness Connector
CED,TX17864,49 –19–03SEP02–2/2
9015A
10
53

092005
PN=129
System Diagrams
Secondary Steering Switch Harness (W17) Component Location (S.N. —590067)
9015A
10
54
–19–05JUN00
T131091
CED,TX17864,51 –19–02JUN00–1/1

092005
PN=130
System Diagrams
Cab Work Lights Harness (W19) Component Location (S.N. —590067)

T105693 –19–19FEB97
TX,10,111547 –19–02JUN00–1/2

092005
PN=131
9015A-10-55 - A 9015A-10-55 - B
System Diagrams
Cab Work Lights Harness (W19) Component Location (S.N. —590067)

T105693 –19–19FEB97
TX,10,111547 –19–02JUN00–1/2

092005
PN=131
9015A-10-55 - A
1/2
der
92005
131
9015A-10-55 - B
System Diagrams
9015A
10
56
–19–05SEP97
T110564
TX,10,111547 –19–02JUN00–2/2

092005
PN=132
System Diagrams
Blower/Air Conditioning Harness (W20) And Component Location Drawing (S.N. —

590067)
T113184 –19–05MAR98
CED,TX03679,3533 –19–18MAR98–1/4

092005
PN=133
9015A-10-57 - A 9015A-10-57 - B
System Diagrams
Blower/Air Conditioning Harness (W20) And Component Location Drawing (S.N. —

590067)
T113184 –19–05MAR98
CED,TX03679,3533 –19–18MAR98–1/4

092005
PN=133
9015A-10-57 - A
1/4
der
92005
133
9015A-10-57 - B
System Diagrams
A—Temperature Control F—Blower Motor 25A Fuse L—Expansion Valve S—Heating/Evaporator Core
Switch (F29) M—Air Conditioning Low T—Freeze Control Switch
B—Blower Speed Switch (S21) G—Receiver/Dryer Pressure Switch (B36) (B35)
C—Air Conditioning (On/Off) H—Air Conditioning Clutch 1 N—Heater Valve U—Air Ducts
Switch (S22) A Diode (V11) O—Pressurizer Motor (M7) V—Blower Speed Resistor (R3)
D—Pressurizer Motor 7.5A I—Condenser P—Fresh Air Filter W—Main Blower Motor (M6)
Fuse (F20) J—Compressor Relief Valve Q—Recirculating Air Filter X—Service and Charge Port
E—Blower/Pressurizer Motor K—Air Conditioning R—Air Conditioning High
Relay (K19) Compressor Clutch (Y16) Pressure Switch (B37)
9015A
10
58

092005
PN=134
System Diagrams
9015A
10
59
–19–31JUL96
T101385

092005
PN=135
System Diagrams
NOTE: Connectors are viewed from the rear (wire)

side.
CED,TX03679,3533 –19–18MAR98–4/4
9015A
10
60

092005
PN=136
System Diagrams
Converter And Power Plug Harness (W21) Component Location (S.N. —590067)
9015A
10
61
–19–05JUN00
T131099
TX,9015,111874 –19–03SEP97–1/1

092005
PN=137
System Diagrams
Secondary Steering Pump Motor Harness (W23) Component Location (S.N. —590067)
9015A
10
62
–19–12FEB98
T113183

092005
PN=138
System Diagrams
9015A
10
63
–19–12FEB98
T113411
CED,TX17864,2 –19–02JUN00–2/2

092005
PN=139
System Diagrams
Battery (Cables) Harness (W24) Component Location (S.N. —590067)
9015A
10
64
–19–10SEP97
T110566
TX,9015,111876 –19–03SEP97–1/1

092005
PN=140
System Diagrams
Radio Harness (W34) Component Location (S.N. —590067)
9015A
10
65
–19–22DEC00
T136669
Radio Harness (W34) Component Location

TX18076,000001C –19–26JAN01–1/1

092005
PN=141
System Diagrams
Electric Air Adjust Seat Harness (W36) Component Location (S.N. —590067)
9015A
10
66
–19–12FEB98
T113196
CED,TX17864,7 –19–11FEB98–1/1

092005
PN=142
System Diagrams
CAN Terminator Harness (W37) Component Location (S.N. —590067)
9015A
10
67
–19–10FEB98
T113359
CED,TX17864,4 –19–10FEB98–1/1

092005
PN=143
System Diagrams
9015A
10
68

092005
PN=144
Group 15
Sub-System Diagnostics
Start Circuit Theory Of Operation (S.N. —

590067)
When the key switch is in the On, Bulb Check or Start

position, power flows through the Transmission Controller
Switched 5 A Fuse (F12) to energize the Shifter Switch
–UN–15NOV02
(S10).
When the key switch is in the START position and the

shifter switch is in the Neutral position, power flows from
T160666
the shifter switch to energize the coil of the Neutral Start
Circuit Relay (K1). When that relay is energized, power
flows from the key switch ST terminal, through the Neutral
Start 5 A Fuse (F3) and the Neutral Start Circuit Relay
(K1) to energize the Start Relay (K3).
9015A
When the start relay is energized, battery power goes to 15
the starter motor coil through the E01 White wire. The coil 1
in the Starter Motor (M1) is energized and direct battery
power is then sent to the starter motor.
The purpose of the Starter Coil Suppression Diode (V1)

and the Start Relay Coil Suppression Diode (V5) is to limit
voltage spikes.
An Emergency Starting Terminal (G2) is located on the

start motor. This terminal provides a convenient positive
connection to emergency start the loader or to connect an
external charger to the batteries.
TX,15,111719 –19–01APR98–1/1

092005
PN=145
Ride Control Circuit Theory Of Operation (S.N. —590067)

T153026 –19–17OCT02
TX,15,111147 –19–23AUG02–1/2

092005
PN=146
9015A-15-2 - A 9015A-15-2 - B
Ride Co
T153026 –19–1
TM2075 (03
9015A-15-2 - A
Control Circuit Theory Of Operation (S.N. —590067)

–19–17OCT02
TX,15,111147 –19–23AUG02–1/2

092005
PN=146
9015A-15-2 - B
When Key Switch is on, power is supplied to Ride dumping bucket. See Ride Control Operation—In the
Control Switch (S31) and relays K30 and K31 through “ON” Postition-Bucket Dump for hydraulic operation.
fuse F30. (Group 9025-05.)
Ride Control Switch “On” Position: With Ride Ride Control Switch AUTO Position: With Ride
Control Switch (S31) on, voltage is sent to the CCU Control Switch (S31) in AUTO, ride control functions
through J02 wire. This tells CCU that ride control is same as on position with one exception. When ground
activated. CCU then supplies power to energize Ride speed is at specification or less, ride control is turned
Control (On/Off) Relay (K31) through J06 wire and off. Ride control will activate after ground speed
Ride Control Boom Relay (K30) through J04 wire. This exceeds specification. CCU controls this by switching
energizes relays Y18 and Y34 to activate ride control. power supplied to relay K31 through J06 wire.
Power is also available at pressure switch B41 when Specification

S31 is on. This pressure switch is located in the Ride Control Switch AUTO
Position—Speed .......................................... 6 km/h (3.5 mph) or less
bucket dump pilot circuit and will close when the
bucket bump function is activated. With B41 closed,
Ride control also functions this way if machine is 9015A
solenoid Y17 is energized. This blocks boom rod end 15
started with ride control switch in on or auto.
oil to tank and prevents boom from dropping when 3
TX,15,111147 –19–23AUG02–2/2

092005
PN=147
Monitor Display Unit Circuit Theory Of Operation (S.N. —590067)

T160606 –19–19OCT02
TX17994,0000340 –19–13AUG02–1/4

092005
PN=148
9015A-15-4 - A 9015A-15-4 - B
Monitor
T160606 –19–1
TM2075 (03
9015A-15-4 - A
itor Display Unit Circuit Theory Of Operation (S.N. —590067)

–19–19OCT02
TX17994,0000340 –19–13AUG02–1/4

092005
PN=148
9015A-15-4 - B
The Monitor Display Unit (MDU) is used to indicate the depending on engine temperature, indicating that
status of machine functions. It is controlled by signals preheating is completed. Light will turn off while
received from the transmission controller unit (A3) and cranking engine.
Chassis Control Unit (A2) along the Controller Area
Network (CAN) link. IMPORTANT: If the “S 065” Engine Oil Pressure
Sensor option is set “On” or “Off”
The MDU (H2) receives service code messages by incorrectly, the Engine Oil Pressure
way of the CAN link from the Chassis Control Unit (A2) Indicator will be On, the “STOP”
(pins D3, E2 and E3 of the 60-pin connector) and from light will flash and the warning alarm
the transmission control unit (A3) (pins 2, 25, and 26). will sound when the engine is idling.
Service Code 0478 will be active.
Described below are all functions of the MDU and the Access Monitor Display Unit Service
machines inputs to these functions.See Electrical Menu and reset the Engine Oil
Component Specifications (S.N. —590067)for all Pressure Sensor option to correct
switch and sender specifications. setting. See Monitor Display Unit
Reconfiguration—Enable Options (S
9015A
Engine Air Filter Indicator Light: The engine air filter 06) for procedure to reset the S 065 15
restriction switch (B19) is a normally open switch that option. See Monitor Display Unit 5
closes to machine ground when a restriction is sensed Reconfiguration—Delete Service
with the engine running. An input signal is sent to the Codes for procedure to delete
Chassis Control Unit (pin Y2 of the 60-pin connector) Service Code 0478.
through the CAN link, to the monitor display unit. The
CAUTION light and indicator light will come on. Engine Oil Pressure Indicator Light: The engine oil
pressure sensor (B23) sends a signal to the Chassis
Transmission Filter Indicator Light: The Control Unit (pins P2, P3 and R3), then through the
transmission oil filter restriction switch (B20) is a CAN link to the monitor display unit.
normally open switch that closes to machine ground
when a restriction is sensed with the engine running. Hydraulic Oil Temperature Indicator Lights: The
An input signal is sent to the Chassis Control Unit (pin hydraulic oil temperature sensor (B15) is an analog
X1 of the 60-pin connector) through the CAN link, to input to the CCU. The CCU will then excite the sensor
the monitor display unit. The CAUTION light and the and read the temperature. A message is sent to the
indicator light will come On. monitor display unit by way of the CAN link.
Hydraulic Oil Filter Indicator Light: The hydraulic oil Battery Voltage Indicator Light: With the engine
filter restriction switch (B21) is a normally open switch running, the battery voltage indicator will come on
that closes to machine ground when a restriction is when alternator voltage is too high or low.
sensed with the engine running. An input signal is sent
to the Chassis Control Unit (pin Y3 of the 60—pin With the engine NOT running and key On, the battery
connector) through the CAN link, to the monitor display voltage indicator will come On when battery voltage is
unit. The CAUTION light and indicator light will come too high or too low.
On.
A signal is sent from the chassis computer by way of
Engine Preheat Indicator: Indicator will light when the CAN link, to the monitor display unit. The
key switch is turned clockwise to the on position. Light CAUTION light and indicator light will come On.
will turn off after approximately 15—45 seconds,
Continued on next page TX17994,0000340 –19–13AUG02–2/4

092005
PN=149
Left Turn Signal/Hazard Indicator Light: The The monitor display unit then determines the
Chassis Control Unit receives a signal (pin W3 of the appropriate warning level, based on the park brake
60—pin connector) from the four-way flasher switch pressure switch status and the “in gear” or “neutral”
(S24). A signal is sent from the Chassis Control Unit status. If the machine is in “neutral,” the park brake
(pin C1 of 30—pin connector) to energize the left indicator light will come on. If the machine is “in gear,”
flasher relay (K23) and turn on the appropriate lights. the park brake indicator light and red STOP light will
flash.
Then a signal is sent from the chassis computer by
way of the CAN link, to the monitor display unit. The Brake Pressure Indicator Light: The service brake
monitor display unit turns on the left turn signal pressure switch (accumulator charge) (B27) is open
indicator. If either of the turn signal switches is On, with normal operating brake pressure. It closes when
then the opposite turn signal bulb will burn steady (On the service brake pressure less than normal and sends
but not flashing). When turn signal switch is turned Off, a signal to the Chassis Control Unit (pin W1, of the
both turn signal bulbs will again flash in 60-pin connector). Then a signal is sent from the
synchronization—hazard mode. Chassis Control Unit by way of the CAN link, to the
monitor display unit.
9015A
15 Right Turn Signal/Hazard Indicator Light: The
6 Chassis Control Unit receives a signal (Pin W3 of the If the engine is running, the monitor display unit turns
60-pin connector) from the four-way flasher switch on the brake pressure light, the flashing red STOP
(S24). A signal is sent from the Chassis Control Unit light, and the audible alarm.
(pin D1 of 30-pin connector) to energize the right
flasher relay (K24) and turn on the appropriate lights. If the engine is not running, the monitor display unit
turns on the brake pressure light and the flashing red
Then a signal is sent from the chassis computer by STOP light with no audible alarm.
way of the CAN link, to the monitor display unit. The
monitor display unit turns on the right turn signal Work Lights Indicator Light: The Chassis Control
indicator. If either of the turn signal switches is On, Unit receives a signal (pin B1 of 60-pin connector)
then the opposite turn signal bulb will burn steady (On from the cab work lights switch (S30). The Chassis
but not flashing). When turn signal switch is turned Off, Control Unit sends the work lights On signal to the
both turn signal bulbs will again flash in monitor display unit by way of the CAN link.
synchronization--hazard mode.
Steering Pressure Light: The steering system
High Beams On Indicator Light: This indicator light is pressure switch (B25) (secondary steering) is closed
not used. during normal operation. The switch opens when
steering pressure is less than normal and sends a
Park Brake On Indicator Light: The park brake signal to the chassis computer (pin X2 , of the 60-pin
pressure switch (B34) is a normally closed switch. connector). A signal is sent from the Chassis Control
Unit by way of the CAN link to the monitor display unit.
When the switch is closed, the park brake is applied
and the indicator light in the monitor display unit is On. If the engine is running, the monitor display unit turns
A signal is sent from the Chassis Control Unit by way on the steering pressure light, the flashing red STOP
of the CAN link, to the monitor display unit. light, and the audible alarm.
The shifter switch (S10) sends an “in gear” or “neutral” If the engine is not running, the monitor display unit
message to the transmission controller. The turns on the steering pressure light and the flashing
transmission controller sends this message to the red STOP light with no audible alarm.
monitor display unit by way of the CAN link.

092005
PN=150
Transmission Service Indicator Light: This indicator indicators will go to 12 o’clock position. During the
will come on only if transmission clutch slippage Bulb Check mode, the audible alarm will sound for 1/2
occurs. second once every second.
When the transmission detects a slippage, the If the monitor display unit gets a signal that the engine
indicator comes on and stays on. the service code speed is greater than 300 rpm or engine oil pressure is
resets when the machine is shut down. not low, it determines that the engine has started, and
the Bulb Check mode will be suspended.
Fasten Seat Belt Indicator Light: The seat belt light
is controlled by the monitor display unit. The light is CAN messages received by the monitor display unit
not directly associated with any switch inputs. The during Bulb Check will be saved and displayed or
fasten seat belt indicator light will be on for the first indicated after the Bulb Check is complete.
five (5) seconds after starting the machine.
Power Up from Switched Power: At power up from
Modes Of Operation switched power, the monitor display unit will initialize
all internal memory and set up all interfaces for normal
9015A
The monitor display unit (H2) has following modes of operation. No information will be displayed for the first 15
operation: second to allow time for inputs to stabilize. The display 7
will be in Bulb Check mode for four seconds, then the
Power Up from Unswitched Power: Press and hold machine model will be shown for three seconds.
down SELECT on the monitor display unit keypad. The
monitor display unit will display the system battery After this "power on" time delay, the gauges, lighted
voltage and the accumulated engine hours on the displays and indicators will display the appropriate
basic display. The engine hours will be retrieved from information based on whether or not the engine is
memory and the battery voltage will be the system running.
battery voltage read by the monitor display unit (at pin
G of the 8-pin connector). The fasten seat belt light will be turned on for the first
five seconds after the engine has started. If during the
Power will be supplied only to the gear indicator first 5 seconds the engine dies, the fasten seat belt
display and its lighting. The voltmeter/odometer line of light will be turned off. If the engine is restarted, the
the display will show the following sequence, changing fasten seat belt light will be turned on again for 5
every 4 seconds: volts, miles, kilometers, repeat. seconds.
When the switch is released, the monitor display unit
will immediately power down. Monitor Display Unit Operation at Power Down:
When the monitor display unit detects that system
Specification battery voltage at the switched power input (pin J) is
Sequence Changes Every— less than 17.5 + or - 0.5 volts, the monitor display unit
Time ..................................................................................... 4 seconds
will assume that a power down is in progress. If the
monitor is in the process of writing to memory, it will
Bulb Check: When the key switch is in the on position
send a signal to the on-board relay. This relay will be
and the engine is not running, the Bulb Check mode
energized and provide unswitched power to the
will be on for five seconds. During the Bulb Check
monitor display unit so that the write to memory can be
mode, all warning lights, the red STOP light and the
completed.
yellow CAUTION light are turned on solid. All
TX17994,0000340 –19–13AUG02–4/4

092005
PN=151
Monitor Display Unit—Accessing Menus (S.N. —590067)
9015A
15
8
–19–13FEB97
T107094
Monitor Display Unit
The monitor display unit has a basic digital LCD Diagnostics menu provides a limited set of tools, and
display window (B) and also a 12 character is intended to be used by service personnel and
alphanumeric message display (A) that provides a text machine operators for diagnostic and troubleshooting
description of the currently displayed mode. This functions.
message display supplements the information that is
shown on the basic display window. The four main Service menu is for service personnel and requires a
menus are: special procedure to gain access. This mode provides
an additional and more sophisticated set of tools for
• Normal Display Menu diagnostics and troubleshooting.
• Accessory Menu
• Diagnostics Menu The monitor display unit keypad is used to scroll
• Service Menu through the different menus and modes of operation.
Key names and general functions are as follows:
Normal menu is displayed when the machine is first
turned on, and no special diagnostic functions are • MENU (C) provides initial entry into the accessories
selected and diagnostics system. Each time MENU is
pressed, display will cycle to the next menu. Once a
Accessory menu allows the operator to make changes main menu has been selected, pressing MENU
to various operating conditions of the machine. again will return to the Normal Display Menu.
Continued on next page TX,9015,111881 –19–01JUL02–1/2

092005
PN=152
• BACK (D) will back out of a menu, one item each Diagnostics modes, SELECT will activate the
time the key is pressed. currently chosen menu.
• NEXT (E) will move to the next selection within a On machines with deluxe display monitor, press
menu or mode. SELECT to toggle battery voltage and sensor
• SELECT (F) switches between volts/kilometers/hours readings between basic digital LCD display window
during normal operation. In the Accessories or and alphanumeric message display window.
TX,9015,111881 –19–01JUL02–2/2
Monitor Display Unit—Normal Display Menu

(S.N. —590067) 9015A
15
9
When key switch is turned on, all lights on display monitor
will come on, alarm will sound and stop and caution lights
will flash.
–19–17FEB98
The basic display window will show the bulb check mode.
The window will contain numerical digit 8’s and will be
shown for approximately 5 seconds.
T113526
Then the machine model number will show in the basic
display window.
Continued on next page TX,15,111807 –19–13AUG02–1/3

092005
PN=153
Approximately five seconds later, the Normal display will

be shown.
NOTE: Press SELECT to alternate between Odometer

and System Voltage display.
–19–28AUG96
When the machine is in neutral, the gear display (A)
shows the gear position of the shift lever. When the
machine is not in neutral, it displays the gear that the
transmission has engaged.
T101985
NOTE: A Diagnostic Trouble Code (DTC) is the same as
Deluxe Monitor Display Unit—Normal Display
Service Code.
A—Gear Display
When the transmission controller diagnostic trouble code B—FNR Display
(DTC) F 1655 occurs, a "---" is shown in this part of the C—Auto Display
9015A D—Tachometer Display
15 display window because there is a Controller Area E—Hour Meter Display
10 Network (CAN) transmittal failure. F—Voltmeter/Odometer Display
G—Basic Display Window
The FNR Display (B) shows the forward, neutral, reverse H—Message Display Window (If Equipped)
status. When a transmission controller unit failure occurs,
this display is blank.
The Auto Display (C) shows whether the transmission

"Auto" mode is On or Off. When a transmission controller
unit failure occurs, this display is blank.
The Tachometer Display (D) shows the torque converter

input shaft rpm to the nearest 5 rpms. When a
transmission controller unit malfunction occurs, a "---" is
displayed and the icon is turned off.
The Hour Meter Display (E) shows the machine hours in

whole hour increments. The hour meter accumulates
hours only when the engine is on; and the icon flashes
once per second. The engine is considered on when the
tachometer is greater than 300 rpm or engine oil pressure
is greater than 89.6 kPa (0.9 bar) (13 psi).
The hour meter displays up to 99,999 hours.
The Voltmeter/Odometer Display (F) shows either the

voltmeter or odometer reading. Press SELECT to toggle
between these readings.

092005
PN=154
On U.S. and Hitachi export machines, the display rotates

from volts to miles to kilometers. On Hitachi domestic
machines, the display rotates from kilometers to volts
only.
The voltmeter displays battery voltage when the machine

is off and system voltage to the nearest tenth when the
machine is on.
The odometer is capable of displaying up to 99,999.9 total

miles (or 999,999 if the decimal point is disregarded).
From 0 to 62,111.7 miles (0 to 99,937.7 km), the
odometer displays both miles and kilometers in tenths.
From 62,111.8 to 99,999.9 miles (99,937.8 to 160,889.8
km) miles are displayed in tenths and kilometers in ones.
From 100,000 miles (160,900 km) on, both miles and
9015A
kilometers are displayed in ones. The odometer runs only 15
when the engine is on. 11
When the 0.1 Hour Meter Mode is turned On in the

Accessory Menu (A 06), machine hours will be displayed
in tenths of hours in the volts/miles/km display. Press
SELECT to toggle between hours and the volts/miles/km
display.
TX,15,111807 –19–13AUG02–3/3
Monitor Display Unit—Accessory Menu

(S.N. —590067)
Clutch Cut-Off (A 01)
At Normal Mode display, press MENU once. Display

–19–15AUG96
window will show A, indicating Accessory Menu.
Press SELECT again; display window shows A 01,

indicating Clutch Cut-Off Mode.
T101986
Clutch Cut-Off Menu (A 01)

092005
PN=155
In the Clutch Cut-Off Mode of operation, there are three

different functions to choose from:
• Level Ground
• Small Slope
• Steep Slope
–19–02SEP97
By turning one of these functions “On”, the other two are
automatically turned “Off”.
T110757
Press SELECT again. Display shows A 011 Level Ground
Setting, If setting shows “Off”, press SELECT again and it
will be “On”, disabling the other two positions. Clutch Cut-Off Menu (A 01)
Press NEXT to move to A 012 Small Slope Setting, and

NEXT again to A 013 Steep Slope Setting. Press SELECT
9015A
15 to choose a setting and disable the other two settings.
12
Level Ground (A 011): When the Level Ground function
is turned “On” in the monitor display unit, the clutch cut-off
enable switch (S11) turned “On”, and the brake pedal is
pressed down, the clutch cut-off sensor (B33), which is a
rotary potentiometer, will sense the position of the brake
pedal linkage by the voltage reading. When it senses
voltage higher than the low voltage set point, the
transmission will “disengage” (release clutch) and
modulate to neutral. In this position the machine will still
roll slightly.
In “Auto” mode, the transmission will “reengage” (apply

clutch) and modulate into the appropriate gear (based on
ground speed) if the Clutch Cut-Off Sensor (B33) voltage
reaches the engagement set point. This voltage is lower
than the clutch cut-off set point.
The transmission will also reengage if the clutch cut-off

enable switch is turned to the “Off” position.

092005
PN=156
Small Slope (A 012): When the Small Slope function is

turned “On” in the monitor display unit, the clutch cut-off
enable switch turned “On”, and the brake pedal is pressed
down, the Clutch Cut-Off Sensor (B33), which is a rotary
potentiometer, will sense the position of the brake pedal
linkage by the voltage reading. When it senses voltage
higher than the medium voltage set point, the
transmission will “disengage” (release clutch) and
modulate to neutral. In this position the machine will still
roll slightly.

9015A
15
The transmission will also reengage if the clutch cut-off 13
Steep Slope (A 013): When the Steep Slope is turned

“On” in the monitor display unit, the clutch cut-off enable
switch turned “On”, and the brake pedal is pressed down,
the Clutch Cut-Off Sensor (B33), which is a rotary
potentiometer, will sense the position of the brake pedal
linkage by the voltage reading. When it senses voltage
higher than the high voltage set point, the transmission
will “disengage” (release clutch) and modulate into neutral.
In this position the machine will still roll slightly.


Quick Shift Mode (A 02)
The Quick Shift mode allows the operator to choose

between Down/Up and Down Only shift functions when
the transmission is in manual or automatic operation.

092005
PN=157
Down/Up: When this function is turned “On”, the

transmission will down shift one gear when the Quick Shift
Switch (S7) (at top of pilot controller handle) is pressed
down once. It is not possible to down shift more than one
gear.
When the quick shift switch is pressed down again, the

transmission will electronically shift up one gear again.
Down Only—Transmission in Manual Operation:When

this function is turned “On”, each time the quick shift
switch (at top of pilot controller handle) is pressed down,
the transmission will shift down one gear (regardless of
selected gear).
If the operator presses down on the quick shift switch

9015A
15 while no shift is taking place, the controller will cause the
14 transmission to shift down one gear (regardless of
selected gear).

while an up shift is taking place, the transmission
controller will cause the transmission to shift down to the
previous gear.

while a down shift is taking place, the transmission
controller will ignore the request for the down shift.
Once a down shift is made by pressing the quick shift

switch, the transmission will not shift up again unless a
direction or gear change is made.
Down Only—Transmission in Automatic Operation: If

the operator presses the quick shift switch when the
transmission is in automatic operation, the transmission
will down shift to one gear below the gear displayed in
basic display window. This change is made independent
from shifter switch selection.
Down Only works basically the same in automatic as in

manual, except it will shift Up or Down from the highest
gear downshifted to.

092005
PN=158
Transmission will automatically shift up or down from the

gear displayed in basic display window until shifter switch
is moved to Neutral. This will cancel down shift mode and
transmission will go back to fully automatic mode.
TX17994,0000341 –19–13AUG02–5/14
Press SELECT at the A 02 Quick Shift display.
–19–04SEP97
9015A
15
T110758
15
Quick Shift Menu (A 02)
TX17994,0000341 –19–13AUG02–6/14
If the A 021 Down/Up display shows OFF, press SELECT

to turn Down/Up shift function On and disable the Down
Only function.
To choose the Down Only shift function, press NEXT.
–19–04SEP97
T110759
Quick Shift Menu—Down/Up Mode

092005
PN=159
At A 022 Down Only display, press SELECT to turn Down

Only shift function “On” and to disable Down/Up function.
–19–09SEP97
T110760
Quick Shift Menu—Down Only Mode
9015A
15
16
TX17994,0000341 –19–13AUG02–8/14
Auto Mode To First (A 03)
In Auto Mode to First, the transmission will shift to first

gear if a high load is sensed while the transmission is
actually in second gear. This shift change is made
independent from shifter switch selection.
–19–02SEP97
A direction change during normal conditions will not cause
the transmission to shift down into first gear. If a direction
change is made during high transmission load conditions,
T110761
the transmission will shift down into first gear.
Press SELECT at the A 03 display. Auto Mode to First Menu (A 03)
Press SELECT again to either turn this option “On” or

“Off”.

092005
PN=160
Job Timer Mode (A 04)
The job timer is a resetable hour meter that can be used

to time tasks to the nearest tenth of an hour.
At the A 04 display, press SELECT.
–19–15AUG96
Then press SELECT again to turn the timer “On” or “Off”.
When the timer is “Off”, press NEXT to reset the timer.
T101991
Job Timer Mode Menu (A 04)
9015A
15
17
TX17994,0000341 –19–13AUG02–10/14
Stop Watch Mode (A 05)
The stop watch is a resetable timer that is used to

measure time in seconds and tenths of seconds.
–19–15AUG96
Then press SELECT again to turn the timer “On” or “Off”.
When the timer is “Off”, press NEXT to reset the timer.
T101992
Stop Watch Mode Menu (A 05)

092005
PN=161
0.1 Hour Meter Mode (A 06)
Then press SELECT again to turn the 0.1 Hour Meter

Mode “On” or “Off”.
–19–15AUG96
T101993
0.1 Hour Meter Mode Menu (A 06)
9015A
15
18
TX17994,0000341 –19–13AUG02–12/14
When the 0.1 Hour Meter Mode is turned “On”, the hour
meter reading can be accessed during normal machine
operation by pressing SELECT. The odometer reading will
switch to the voltmeter reading, and then to the hour
meter reading (A) in hours and tenths of hour.
–19–28AUG96
When the 0.1 Hour Meter Mode is turned “Off”, only the
odometer reading and voltmeter are available.
The 0.1 Hour Meter Mode “On” or “Off” position stays set
T101994
after machine shut down.
0.1 Hour Meter Mode Menu (A 06)

092005
PN=162
Metric Units Mode (A 07)
This mode allows the technician to choose between metric

and English unit displays.
–19–15AUG96
Press SELECT to turn Metric Units display “On” or “Off”.
When Metric Units mode is “On”, all values will be shown
T101995
in metric. When Metric Units mode is “Off”, all values will
be shown in English units.
Metric Units Mode Menu (A 07)
9015A
15
19
TX17994,0000341 –19–13AUG02–14/14
Monitor Display Unit—Diagnostics Menu

(S.N. —590067)
Diagnostic Trouble Code (DTC) (d 01)
–19–02SEP97
a Service Code. The term DTC conforms with the
standards set by the Society of Automotive
Engineers (SAE).
T110762
NOTE: DTC can also be viewed using SERVICE
ADVISOR™ system. See Diagnostic Trouble
Codes (DTC) (S.N. —590067). (Group 9005-10.) Service Codes Menu (d 01)
This mode displays the eight highest priority Diagnostic

Trouble Codes (DTCs) which have occurred on the
machine.
At the d 01 display, press SELECT.
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page TX17994,0000343 –19–16AUG02–1/47

092005
PN=163
An F is shown in the display window to indicate diagnostic

trouble code (DTC) mode. The first diagnostic trouble
code (DTC) number is shown.
To obtain additional information about the first diagnostic

trouble code (DTC), press SELECT again.
–19–02SEP97
T110763
DTC Menu (d 01)
9015A
15
20
TX17994,0000343 –19–16AUG02–2/47
NOTE: Diagnostic Trouble Codes (DTC) can be deleted

from memory in this menu by doing the following:
Press and hold SELECT for three seconds.
Audible beeps will alert the technician that a code
–19–15AUG96
is to be deleted.
The display window will show the hour meter reading at

first occurrence of the diagnostic trouble code (DTC).
T101997
To obtain additional information about the diagnostic
DTC Menu (d 01)
trouble code (DTC), press NEXT

092005
PN=164

last occurrence of the diagnostic trouble code and the
total number of occurrences.
–19–15AUG96
T101998
DTC Menu (d 01)
9015A
15
21
TX17994,0000343 –19–16AUG02–4/47
To move to the second diagnostic trouble code, press

BACK until the Fxxxx display is shown. This example: F
1645.
Then press NEXT.
–19–02SEP97
T110763
DTC Menu (d 01)

092005
PN=165
Continue to scroll through Diagnostic Trouble Codes

(DTCs) using this sequence until END is shown in the
display window.
To delete codes press and hold SELECT for at least three

seconds while each code is displayed.
–19–15AUG96
NOTE: When F END shows in display window, technician
can access Service Menu. This menu is NOT to
be used by the operator—only by service
T101999
technicians. Press SELECT and hold down for at
least five seconds. An S in the display window
DTC Menu (d 01)
indicates Service Menu.
See Monitor Display Unit—Service Menu (S.N. —

590067) (Group 9015A-15) for detailed
9015A
15 instructions on using this menu.
22
Continuity Check (d 02)
In this diagnostic mode, sensors and circuits connected to

the Chassis Control Unit (CCU) are monitored for a "state
of change." Examples of "state of change" are switches
going from open to closed or closed to open, circuit shorts
and opens, high rate of change from analog sensors, and
changes in digital speed sensor outputs.
TX17994,0000343 –19–16AUG02–6/47
Two different "continuity check" modes are provided.

Press SELECT to choose the mode wanted.
"With Speed Sensors" (d 021) mode monitors all circuits

–19–02SEP97
and sensors. This mode is useful when the machine is

parked with the engine off.
"Without Speed Sensors" (d 022) monitors everything

T110764
except the digital speed sensors. This mode is useful

when the engine is running and/or the machine is rolling,
when the engine, transmission and wheel speed sensors Continuity Check Menu (d 02)
are pulsing continuously.

092005
PN=166
After one of the continuity check modes is selected, the

display window will be in a waiting position until a "state of
change" is detected.
–19–15AUG96
T102000
Continuity Check Menu (d 02)
9015A
15
23
TX17994,0000343 –19–16AUG02–8/47
Whenever a "change of state" is detected, the warning

horn will "beep" to inform the technician of the change
The circuit device component number and section number
as it appears on the system functional schematic will
show on the basic display window.
–19–15AUG96
Press SELECT to display sensor data and units in the
message display window. Press SELECT again or BACK
to remove the information from the message window.
Press NEXT to move to the next sensor display.
T102001
The audible alarm can be used to verify that a switch is
Continuity Check Menu (d 02)
changing state when it is activated (or is not changing
state when it should be, if there is no beep.) Also, by
moving a potentiometer type control slowly through its
operating range, a break or "bad spot" can be detected.
Following is a listing of components that can be “continuity

checked” in the monitor display unit Diagnostics menu.

092005
PN=167
Component Identification Message Display In Functional Schematic and Wiring Harness Location
No. and Name Monitor Display Unit
B8 Hydraulic System Hydraulic Pressure Sensor SE16
Pressure Sensor Circuit W5 Engine Frame Harness
B14 Throttle Position Sensor Throttle Sensor Circuit SE16
Load Center Harness (W3)
B15 Hydraulic Oil Hydraulic Oil Temperature SE19
Temperature Sensor Sensor Circuit W5 Engine Frame Harness
B1 Engine Coolant Engine Coolant Temperature SE19
Temperature Sensor Sensor Circuit W6 Engine Harness
B17 Fuel Level Sender Fuel Level Sensor Circuit SE19
W5 Engine Frame Harness
B19 Engine Air Filter Engine Air Filter Switch SE20
Restriction Switch Circuit W6 Engine Harness
B20 Transmission Oil Filter Transmission Oil Filter SE20
Restriction Switch Switch Circuit Transmission Harness (W10)
9015A
B21 Hydraulic Oil Filter Hydraulic Oil Filter Switch SE20
15
Restriction Switch Circuit W5 Engine Frame Harness
24
B23 Engine Oil Pressure Engine Oil Pressure Circuit SE21
Sensor W6 Engine Harness
B25 Steering System Steering Pressure Switch SE21
Pressure Switch Circuit W17 Secondary Steering Switch Harness
B27 Service Brake Pressure Brake Pressure Switch SE21
Switch Accumulator Charge Circuit W3 Load Center Harness
B28 Torque Converter Input Torque Input Speed Sensor SE22
Speed Sensor Circuit W10 Transmission Harness
B29 Torque Converter Torque Output Speed SE22
Output Speed Sensor Sensor Circuit W10 Transmission Harness
B30 Internal Clutch Speed Internal Clutch Speed SE22
Sensor Sensor Circuit W10 Transmission Harness
B31 Transmission Output Output Speed Sensor Circuit SE22
Shaft Speed Sensor W10 Transmission Harness
B32 Transmission Oil Transmission Oil SE24
Temperature Sensor Temperature Sensor Circuit W10 Transmission Harness
B33 Clutch Cut-Off Sensor Clutch Cut-Off Pressure SE24
Sensor Circuit W3 Load Center Harness
B34 Park Brake Pressure Park Brake Pressure Switch SE24
Switch Circuit W2 Loader Frame Harness
B40 Brake Light Pressure Brake Light Pressure Switch SE37
Switch Circuit W3 Load Center Harness
F11 CCU 28V Switched MDU System Voltage Circuit SE21
Power 7.5A Fuse W3 Load Center Harness
S5 Spin Control Switch Spin Control Rocker Circuit SE16
W14 Spin Control Harness
S6 Automatic Transmission Auto Rocker Circuit SE22
Switch W3 Load Center Harness

092005
PN=168
Component Identification Message Display In Functional Schematic and Wiring Harness Location
No. and Name Monitor Display Unit
S8 Park Brake Release Park Brake Rocker Circuit SE22
Switch W4 Front Console Harness
S19 Front Wiper Switch Front Wiper Switch Circuit SE29
W3 Load Center Harness
S20 Rear Wiper Switch Rear Wiper Switch Circuit SE30
S24 4-Way Flasher Switch Hazard Light Rocker Circuit SE34
S25 Turn Switch Left Turn Switch Circuit SE35
W4 Front Console Harness
S25 Turn Switch Right Turn Switch Circuit SE35
W4 Front Console Harness
S26 Drive and Tail/Marker Drive Light Rocker Switch SE35
Light Switch W3 Load Center Harness
9015A
S26 Drive and Tail/Marker Marker Light Rocker Circuit SE35
15
Light Switch W3 Load Center Harness
25
S30 Cab Work Light Switch Work Light Rocker Switch SE38
S31 Ride Control Switch Ride Control On Rocker SE10
Circuit W3 Load Center Harness
S31 Ride Control Switch Ride Control Auto Rocker SE10
Circuit W3 Load Center Harness
S33 Spin Control Mode Spin Control Mode Select SE16
Switch Circuit W14 Spin Control Mode Harness
TX17994,0000343 –19–16AUG02–11/47
Battery Monitor (d 03)
This mode allows the technician to view the current

voltage of the left and right batteries.

–19–28AUG96
Battery voltage will be displayed in basic display window.

T102003
Battery Monitor Menu (d 03)

092005
PN=169
Press SELECT again to display reading in the

alphanumeric message display. Pressing SELECT will
toggle the reading in and out of the alphanumeric window.
Engine Sensors (d 04)
–19–02SEP97
This mode allows the technician to monitor all engine
sensors that are accessible to the computer system.
See Electrical Component Specifications (S.N. —590067)
T110767
for sensor specifications. (Group 9015A-20.)
Battery Monitor Menu (d 03)
9015A
15
26
TX17994,0000343 –19–16AUG02–13/47
Press SELECT at the d 04 display.
–19–02SEP97
T110766
Engine Sensor Diagnostic Menu (d 04)

092005
PN=170
The d 041 display for Engine Coolant Temperature will be

shown. Temperature will be displayed in °C or °F
(depending on setting selected in A 07 mode) and sensor
voltage will be displayed.
–19–15AUG96
T102004
Coolant Temperature Menu (d 041)
9015A
15
27
TX17994,0000343 –19–16AUG02–15/47

toggle reading in and out of the alphanumeric window.
Press NEXT.
–19–02SEP97
T110769
Coolant Temperature Menu (d 041)

092005
PN=171
The d 042 display for Engine Oil Pressure will be shown.

Pressure will be displayed in kPa or psi and sensor
voltage will be displayed.
–19–15AUG96
T102027
Engine Oil Pressure Menu (d 042)
9015A
15
28
TX17994,0000343 –19–16AUG02–17/47

toggle reading in and out of alphanumeric window.
Press NEXT.
–19–02SEP97
T110771
Engine Oil Pressure Menu (d 042)

092005
PN=172
The d 043 display for Throttle sensor voltage will be

shown.
–19–02SEP97
T110772
Throttle Sensor Menu (d 043)
9015A
15
29
TX17994,0000343 –19–16AUG02–19/47

Press NEXT.
–19–17FEB98
T113547
TX17994,0000343 –19–16AUG02–20/47
The d 044 display for Fuel Temperature will be shown.
–19–31MAR98
T114614

092005
PN=173

Press NEXT.
–19–31MAR98
T114615
TX17994,0000343 –19–16AUG02–22/47
The d 047 display for Intake Manifold Air Temperature will INTAKE MANIFOLD
9015A be shown.
15
30 Press SELECT again to display reading in the
–19–01JUL02
Transmission Sensors (d 05)
This mode allows the technician to monitor all
T156451
transmission sensors that are accessible to the computer
system.
TX17994,0000343 –19–16AUG02–23/47

for sensor specifications. (Group 9015A-20.)Press
SELECT at the d 05 display.
–19–05AUG97
T110773
Transmission Sensors Diagnostic Menu (d 05)

092005
PN=174
The d 051 Oil Temperature Sensor display will show the

oil temperature in °C or °F (depending on setting selected
in A 07 mode) and sensor voltage.
–19–15AUG96
T102007
Oil Temperature Menu (d 051)
9015A
15
31

092005
PN=175

Press NEXT.
–19–02SEP97
The d 052 Clutch Cut-Off Sensor display will show the
Clutch Cut-Off Sensor (B33) voltage.
Press NEXT.
T110775
The d 053 Torque Input Speed Sensor display will show
the speed in rpm. Oil Temperature Menu (d 051)
Press NEXT.
9015A
15 The d 054 Torque Output Speed Sensor display will show
32 the speed in rpm.
Press NEXT.
The d 055 Internal Clutch Speed Sensor display will show

the speed in rpm.
Press NEXT.
The d 056 Output Shaft Speed Sensor display will show

the speed in rpm.
Hydraulic Sensors (d 06)

for sensor specifications. (Group 9015A-20.)

092005
PN=176
This mode allows the technician to monitor all hydraulic

sensors that are accessible to the computer system.
–19–02SEP97
T110776
Hydraulic Sensors Diagnostic Menu (d 06)
9015A
15
33
TX17994,0000343 –19–16AUG02–27/47
The d 061 Oil Temperature Sensor display will show the

temperature in °C or °F (depending on setting selected in
A 07 mode) and sensor voltage.

–19–15AUG96
Press NEXT.
T102008
Oil Temperature Menu (d 061)
TX17994,0000343 –19–16AUG02–28/47
The d 062 Pump Output Pressure display will show the

pressure in kPa or psi (depending on setting selected in A
07 mode) and sensor voltage.
–19–17FEB98
T113559

092005
PN=177

Press NEXT.
–19–17FEB98
T113565
TX17994,0000343 –19–16AUG02–30/47
The d 063 Boom Position Volt Sensor display will show BOOM POSITION
9015A voltage at the sensor (depending upon boom position).
15
34 Press SELECT again to display reading in the
–19–01JUL02
T156458
- +
VOLTS
TX17994,0000343 –19–16AUG02–31/47
Two different fan speed test modes are provided from the
d 064 menu:
Pressing SELECT once will enter into fan speed high test
–UN–29OCT02
mode (d 0641).
Pressing NEXT will enter into fan speed low test mode (d
0642).
T161033
TX17994,0000343 –19–16AUG02–32/47
This mode enables the proportional fan to test fan speed

at highest setting (0 volts to proportional coil).
–UN–29OCT02
T161034

092005
PN=178
This mode enables the proportional fan to test fan speed

at slowest setting (12 volts to proportional coil).
–UN–29OCT02
T161035
TX17994,0000343 –19–16AUG02–34/47
Fuel Sensor (d 07)

9015A
See Electrical Component Specifications (S.N. —590067) 15
for sensor specifications. (Group 9015A-20.)This mode 35
allows the fuel level sensor to be monitored.
–19–09SEP97
Press SELECT at the d 07 Fuel Sensor display.
The Fuel Sensor display will show fuel level in gal or L

(depending on setting selected in A 07 mode) and sensor
T110780
voltage.
Deluxe Monitor Display Unit
TX17994,0000343 –19–16AUG02–35/47

–19–09SEP97
T110781
Deluxe Monitor Display Unit

092005
PN=179
Spin Control Mode (d 09)
NOTE: Menu (d 08) is not used.
This mode allows the technician to monitor the Spin

Control Function operation.
–UN–29OCT02
The Spin Control Mode display will show the Spin Control
T161051
number and the Spin Control Mode Switch (S33) voltage
signal to chassis controller unit.
9015A
15
36
TX17994,0000343 –19–16AUG02–37/47

–19–17FEB98
T113579
SPECIFICATIONS
DISPLAY WINDOW MESSAGE COMPONENT MONITORED SPECIFICATION
d 09 Spin Control Mode Spin Control Mode Switch (S33) Position 1: 0.0—0.15 volts
Position 2: 0.15—0.53 volts

092005
PN=180
Machine Identification Mode (d 10)
This mode provides the technician with machine

identification information for hour meter readings, part
numbers and serial numbers of the monitor display unit,
transmission controller unit, and chassis controller unit.
–19–09SEP97
T110784
Machine I.D. Mode Menu (d 10)
9015A
15
37
TX17994,0000343 –19–16AUG02–39/47
The d 101 MDU Original display will show the monitor

display unit hour meter reading and the original monitor
display unit serial number.
–19–02SEP97
T110782
MDU Original Display

092005
PN=181
Press NEXT.
The d 102 CCU Original display will show the chassis

controller unit hour meter reading and the original chassis
controller serial number.
–19–12SEP96
T102012
CCU Original Display
9015A
15
38
TX17994,0000343 –19–16AUG02–41/47
Press NEXT.
The d 103 MDU Part Number display will show the

monitor display unit part number and serial number.
–19–02SEP97
T110785
MDU Part Number Display

092005
PN=182
Press NEXT.
The d 104 CCU Part Number display will show the

chassis controller unit part number and serial number.
–19–02SEP97
T110786
CCU Part Number Display
9015A
15
39
TX17994,0000343 –19–16AUG02–43/47
Press NEXT.
The d 105 MDU Software Number display will show the

monitor display unit software number.
–19–02SEP97
T110787
MDU Software Number Display

092005
PN=183
Press NEXT.
The d 106 CCU Software Number display will show the

chassis controller unit software number.
–19–02SEP97
T110788
CCU Software Display Number
9015A
15
40
TX17994,0000343 –19–16AUG02–45/47
Press NEXT.
The d 107 TCU Serial Number display will show the

transmission controller unit serial number.
–UN–22OCT97
T111711
TX17994,0000343 –19–16AUG02–46/47
Press NEXT.
The d 108 TCU Software Number display will show the

transmission controller unit software number.
–UN–22OCT97
T111712
TX17994,0000343 –19–16AUG02–47/47

092005
PN=184
Monitor Display Unit—Service Menu (S.N. —

590067)
Accessing Service Menu
IMPORTANT: Whenever a monitor display unit (MDU),

Chassis Control Unit (CCU), or
transmission control unit (TCU) is
replaced, the monitor display unit must
be “reconfigured.” This reconfiguration
procedure is performed in the Service
Menu.
1. Turn key switch On. All lights on display monitor will

come on, alarm will sound and stop and caution lights
will flash. The basic display window will show the bulb 9015A
check mode. The window will contain numerical digit 15
8’s and will be shown for approximately 5 seconds. 41
2. Then the machine model will show in the basic display

window.
3. Approximately 5 seconds later, the Normal Gear LCD

display will be shown.
4. When the Normal Gear LCD display is shown, press

the MENU key once. Display window will show “A”
indicating Accessory menu.
5. Press MENU key again. Display window will show “d”

indicating Diagnostics Menu.

Service Code.
6. Press SELECT key. Display window will show “d 01”

indicating diagnostic trouble code (DTC) mode.
7. Press SELECT key again. Display window will show

“F” and the first diagnostic trouble code (DTC) number.
8. Press NEXT key. Display will show “F” and the

diagnostic trouble code (DTC) number.

092005
PN=185
9. Continue to press NEXT key until “F End” shows in the

display window. Press and hold SELECT for at least 5
seconds until “S” is displayed, which indicates Service
Menu. The Service Menu is to be used only by
service technicians.
NOTE: After reconfiguration procedure is done,

Diagnostic Trouble Code (DTC) F0478 and/or F
1699 may be displayed. If so, clear these
diagnostic trouble codes.
TX17994,0000342 –19–16AUG02–2/15
Machine Model (S 01)

9015A
15 At the S display, press SELECT.
42
–19–02SEP97
T110790
Service Menu Display

092005
PN=186
At the S 01 display, press SELECT again.
This mode initially will display the current machine model

that was programmed at the factory. Press SELECT to
verify that correct machine model is displayed. This model
will be stored and “Done” will be displayed to confirm the
–19–02SEP97
selection.
If the incorrect machine model is displayed:
T110791
1. Apply the park brake. Move shifter lever to Neutral
position. Once the Service Menu is accessed, press
SELECT and “S 01” will be displayed. Machine Model Display (S 01)
2. At the “S 01” display, press SELECT again, to see the

currently configured model. If correct model is shown,
9015A
press SELECT to confirm it. 15
43
If this screen does not show the correct model, press
NEXT to scroll through the machine models until the
correct model is displayed. Then press SELECT.
3. If reconfiguration is successful, DONE will be

displayed. If reconfiguration is not successful, FAIL will
be displayed (about two seconds), and procedure must
be repeated.
4. Press BACK to “S 01.”
5. Press NEXT to get to “S 02.” Press NEXT again to get

to “S 03.”
Tell-Tale Service Codes (S 02)
This mode stores and displays Tell-tale service codes

used to provide historical information on service and
warranty related items.
NOTE: See Diagnostic Trouble Codes (DTC) (S.N. —

590067) (Group 9005-05) for additional
information on Tell-Tale Service Codes.
The tell-tale service codes are:
• 0300 Trans. Oil Temperature High Long

• 0400 Eng. Oil Pressure Low Duration
• 0500 Eng. Coolant Temp. High Long
• 1647 Machine Odometer Bad

092005
PN=187
• 1648 Machine Hourmeter Bad

• 1649 CCU Hourmeter Bad
• 2100 Hydraulic Oil Temperature High Long
The service code list will show the most recent codes at
the top and the oldest codes being removed from the
bottom of the list. A running total of occurrences over the
life of the machine is kept for each service code in the
set, and this total is part of the service code that is
transmitted over the Controller Area Network (CAN).
TX17994,0000342 –19–16AUG02–5/15
At the Tell-Tale Service Code display (S 02), press

9015A SELECT.
15
44
–19–02SEP97
T110792
Tell-Tale Service Codes Display (S 02)
TX17994,0000342 –19–16AUG02–6/15
An F is shown in the display window to indicate service

code mode. This first service code number is shown.
To move to the second service code, press NEXT.
To obtain additional information about the first service

–19–15AUG96
code, press SELECT again.

T102019

092005
PN=188
This display window will show the hour meter reading at

first occurrence of the service code.
To obtain additional information about the service code,

press NEXT.
–19–15AUG96
T102020
9015A
15
45
TX17994,0000342 –19–16AUG02–8/15

last occurrence of the service code and the total number
of occurrences.
–19–15AUG96
T102021

092005
PN=189
To move to the second service code, press BACK until

the Fxxxx display is shown.
Then press NEXT.
Continue to scroll through the service codes using this
–19–15AUG96
sequence until End is shown in the display window.
T102019
9015A
15
46
TX17994,0000342 –19–16AUG02–10/15
Tire Size (S 03)
At the S 03 display, press SELECT.
–19–02SEP97
T110794
Tire Size Display (S 03)

092005
PN=190
This mode initially will display the current machine tire

size that was programmed at the factory. The tire size will
be stored and “Done” will be displayed to confirm the
selection.
If the incorrect machine tire size is displayed:
–19–02SEP97
NOTE: The park brake MUST be set (indicator light will
be On) and the shifter switch MUST be in Neutral
for reconfiguration procedure.
T110795
1. Press NEXT to scroll through the different size options
until the correct tire size is displayed. Then press Tire Size Display (S 03)
SELECT.
2. If reconfiguration is successful, DONE will be

9015A
displayed. If reconfiguration is not successful, FAIL will 15
be displayed (about two seconds), and procedure must 47
be repeated.
3. Press BACK to “S 03.”
4. Press NEXT until “S 06” displays.
Enable Options (S 06)
The Enable Options mode allows the technician to turn

the following machine options “On” (enable) or “Off”
(disable) at the chassis controller unit:
• (S 061) Secondary Steering

• (S 062) Spin Control
• (S 063) Engine Air Heater
• (S 064) Ride Control
• (S 065) Engine Oil Pressure Sensor

092005
PN=191
At the S 06 display, SELECT.
–19–02SEP97
T110797
Enable Options Display (S 06)
9015A
15
48

092005
PN=192
The S 061 Secondary Steering mode will show in display

window. Display will show whether that option is “On” or
“Off”. To change a setting:
NOTE: The park brake MUST be set (indicator light will

be “On”) and the shifter switch MUST be in
–19–09SEP97
Neutral for reconfiguration procedure.
NOTE: If reconfiguration of machine model has been

successful, all options in this menu will be turned
T110796
“Off.” These must be reset to “On”.
If an option already shows “On” cycle it to “Off” Secondary Steering Display (S 061)
then back to “On.” This is a verification to make
sure monitor display unit is receiving the latest
information from the Chassis Control Unit, and the
9015A
option is definitely set to “On.” 15
49
1. At the Service Menu “S 06” Enable Options mode,
press SELECT to display “S 061” Secondary Steering
option.
2. Press SELECT again to enable (turn “On”) or disable

(turn “Off”) this function. If machine is equipped with
secondary steering option, the secondary steering will
operate, even if option is turned “Off”.
3. Press NEXT to move from one option to the next.

Press SELECT to enable or disable each function.
IMPORTANT: If “S 065” Engine Oil Pressure Sensor

option is set “On” or “Off” incorrectly,
the Engine Oil Pressure Indicator will be
On, the “STOP” light will flash and the
warning alarm will sound when the
engine is idling. Service Code F0478
will be active.
4. The “S 065” option is Engine Oil Pressure Sensor. “S

065” must be set to “On.”
5. After enabling all the appropriate options, press MENU

key to return to Normal Gear LCD display.

092005
PN=193
IMPORTANT: After the reconfiguration procedure is

complete, key switch must be turned
“Off” then back “On” before the
transmission control unit (TCU) will
allow the transmission to shift into
gear.
6. Turn key switch “Off” and then back “On.”
TX17994,0000342 –19–16AUG02–15/15
9015A
15
50

092005
PN=194
Chassis Control Unit Circuit Theory Of Operation (S.N. —590067)

T159428 –19–26SEP02
TX,15,111831 –19–17SEP02–1/3

092005
PN=195
9015A-15-51 - A 9015A-15-51 - B 9015A-15-51 - C 9015A-15-51 - D 9015A-15-51 - E
Chassis Control Unit Circuit Theory Of Operation (S.N. —5

T159428 –19–26SEP02
TM2075 (03MAR05) 9015A-15-51
9015A-15-51 - A
s
. —590067)
TX,15,111831 –19–17SEP02–1/3
644J and 724J Loader

092005
PN=195
9015A-15-51 - B
9015A-15-51 - C
9015A-15-51 - D
9015A-15-51 - E
9015A-15-51 - Blank
The basic functions of the Chassis Control Unit are: Left Turn Signal Output from CCU to Relay: The
Chassis Control Unit (pin C1 of 30—pin connector)
• Monitor machine functions sends an output signal to energize the left flasher relay
• Control monitor display unit (K23).
• Transfer hydraulic/transmission systems
communications Right Turn Signal Output from CCU to Relay: The
Chassis Control Unit (pin D1 of 30—pin connector)
Following is the list of functions that work in sends an output signal to energize the right flasher
conjunction with the Chassis Control Unit: relay (K24).
Intermittent Wipers Circuit Signals Drive Lights And Work Lights Signals
See System Functional Schematic (S.N. —590067), See System Functional Schematic (S.N. —590067)
SE29 and SE30 for wiper circuit schematic. (Group SE36 and SE38 for Drive Lights And Work Light
9015A-10.) schematic. (Group 9015A-10.)
9015A
15 Front Wipers Intermittent Switch Input to CCU: The The Chassis Control Unit (A2) reads the input of the
52 chassis computer unit (pin T2 of 60—pin connector) cab work light switch (S30) and will transmitted to the
receives a digital signal input from the front wiper monitor display unit (H2) by way of the Controller Area
switch (S19) when it is in the I (Intermittent) position. Network (CAN) link, to turn the work light indicator on
the monitor On or Off.
Rear Wipers Intermittent Switch Input to CCU: The
chassis computer unit (pin T3 of 60—pin connector) The status of the cab work light switch will be
receives a digital signal input from the rear wiper transmitted from the Chassis Control Unit to turn the
switch (S20) when it is in the I (Intermittent) position. work lights (E20, E21, E22, E23) On or Off.
Front Wipers Output from CCU to Relay: The Tail Lights Signals
chassis computer unit (pin J1 of 30—pin connector)
sends an output signal to energize the front See System Functional Schematic (S.N. —590067)
intermittent wiper relay (K16). SE35 for tail light schematic. (Group 9015A-10.)
Rear Wipers Output from CCU to Relay: The The Chassis Control Unit (A2) reads the input of the
chassis computer unit (pin F3 of 30—pin connector) Drive and Tail Light Switch (S26) and determine which
sends an output signal to energize the rear intermittent tail lights should be on.
wiper relay (K18).
Battery Monitoring Signals
Flasher and Turn Light Signals
See System Functional Schematic (S.N. —590067)
See System Functional Schematic (S.N. —590067) SE19—SE22 for power schematic. (Group 9015A-10.)
SE34 for Flasher and Turn Light schematic. (Group
9015A-10.) There is a 12-volt tap between the batteries, which
powers the CCU 12 V Battery Unswitched Fuse (F9).
Flasher Signal (On/Off) Switch Input to CCU: The The fuse sends an input signal to Chassis Control Unit
Chassis Control Unit (pin W3 of 60—pin connector) (pin A3 of 60-pin connector). The CCU will read this
receives a signal input from the 4—way flasher switch value and transmit the voltage to the monitor display
(S24). unit by way of the Controller Area Network (CAN) link.
Continued on next page TX,15,111831 –19–17SEP02–2/3

092005
PN=196
Using the 12-volt measurement from CAN and the • Secondary Steering Circuit. See Secondary Steering
system battery voltage value displayed on the Circuit Theory of Operation. (This Group.)
voltmeter, the MDU will calculate the voltage level of • Engine Air Heater Circuit. See Engine Air Heater
the second battery. System battery voltage minus Circuit Theory of Operation. (This Group.)
12-volt measurement from CAN equals voltage • Gauge and Indicators Circuits. See Monitor Display
Unit Theory of Operation. (This Group.)
There are five different service codes that can register • Brake and Light Circuit. See Chassis Control Unit
when system voltage is abnormal. Circuit Theory Of Operation. (This Group.)
• Spin Control Circuit. See Spin Control Circuit Theory
See Service Code Verification in Group 9015—20 for Of Operation. (This Group.)
additional information on Diagnostic Trouble Codes. • Pilot Enable/Boom Down Circuit. See Pilot
Enable/Boom Down Circuit Theory of Operation.
• Ride Control Circuit. See Ride Control Circuit Theory (This Group.)
of Operation. (This group)
9015A
15
53
TX,15,111831 –19–17SEP02–3/3

092005
PN=197
Spin Control Circuit Theory Of Operation (S.N. —590067)
9015A
15
54
–19–19SEP02
T159426
Continued on next page TX17994,0000348 –19–21SEP02–1/2

092005
PN=198
NOTE: Spin Control functions same as Load pressure is sensed by the Hydraulic System Pressure
Performance Management (Spin Control) in Sensor (B8).
previous MH loader series.
Switch Position Engine rpm
The Spin Control circuit reduces engine rpm under 1 1900
high hydraulic pressure to reduce the pushing force 2 1825
going into a pile, so boom can lift easier. As engine 3 1750
rpm decreases rim pulling force at wheels also
4 1675
decreases. However hydraulic lifting force remains
fairly constant over selected rpm droop levels. The five 5 1600
position Spin Control Mode Switch (S33) sends five
different voltages to the chassis controller unit, which See Spin Control Check to check system. (Group
in turn dictates the proper engine rpm. The hydraulic 9005-10.)
9015A
15
55
TX17994,0000348 –19–21SEP02–2/2

092005
PN=199
Transmission Control Unit Circuit Theory Of Operation (S.N. —590067)

T159430 –19–17OCT02
TX,15,111797 –19–10MAR99–1/3

092005
PN=200
9015A-15-56 - A 9015A-15-56 - B 9015A-15-56 - C
9015A-15-56 - A
Transmission Con
T159430 –19–17OCT02
TM2075 (03MAR05)
9015A-15-56 - B
Control Unit Circuit Theory Of Operation (S.N. —590067)
TX,15,111797 –19–10MAR99–1/3
9015A-15-56 644J and 724J Loader

092005
PN=200
9015A-15-56 - C
9015A-15-56 - Blank
NOTE: The Transmission Controller (A3) also sends Torque Converter Output Speed Sensor (B29): This
signals to operate the Back Up Alarm Circuit, sensor is located on the right side of the transmission
the Park Brake Sensing Circuit and the Park and monitors torque converter out speed.
Brake Release Circuit.
Internal Clutch Speed Sensor (Transmission) (B30):
When the Key Switch (S1) is Off, battery power flows This sensor is located on the right side of the
from the Transmission Controller Unswitched 5 A Fuse transmission and monitors the speed that the clutch
(F4) to pins 23 and 68 of the transmission controller. packs are turning.
IMPORTANT: After reconfiguration procedure is Output Shaft Speed Sensor (Transmission) (B31)
done on the monitor display unit, the This sensor is located on the right side of the
key switch must be turned “Off” transmission control valve and monitors transmission
then back to “On” before the output shaft speed.
transmission control unit (TCU) will
allow the transmission to shift into These sensors send signals to the transmission
gear. controller. The transmission controller then, sends
9015A
varying electrical signals based on speed and load to 15
When the key switch is in the On or Start position, the proportional solenoids in the transmission control 57
power flows from the IGN terminal of the key switch, valve. This controls the speed of clutch engagement
through the Transmission Controller Switched 5 A during a shift. All of the proportional solenoid valves
Fuse (F12) to pin 45 of the transmission controller. are identical
The transmission controller runs a diagnostic check for
approximately one second upon initial start up. The • Y1 solenoid engages reverse clutch pack
shifter switch must be in Neutral position for a few • Y2 solenoid engages forward high-range clutch pack
seconds after machine is started or machine will not • Y3 solenoid engages first speed clutch pack
move. • Y4 solenoid engages third speed clutch pack
• Y5 solenoid engages forward low-range clutch pack
If shifter switch is not in neutral at start up, it must be • Y6 solenoid engages second speed clutch pack
moved back to neutral, and then to the desired gear
before the machine will move. The transmission controller will limit downshifting of the
transmission if the machine is moving too fast as
When the shifter switch is moved to Forward, Neutral indicated by the magnetic pickup. If the machine is
or Reverse, an input signal is sent to the transmission moving faster than 20% higher than the next higher
controller. The transmission controller will then activate gear at wide open throttle, then the transmission will
the appropriate solenoids in the transmission control not downshift.
valve for the desired movement. When the Clutch
Enable Switch (S11) is turned On and there is input With the machine coasting in neutral, the transmission
voltage from the Clutch Cut-Off Sensor (B33) to Pin controller will not allow the transmission to engage too
38, the transmission will be in Neutral. low of a gear to cause engine overspeed. The gear
appropriate for the ground speed will be engaged, and
There are four speed sensors in the transmission then the transmission will downshift to the selected
control circuit. gear. If the machine is coasting in neutral at a speed
greater than fourth gear wide open throttle, only fourth
Torque Converter Input Speed Sensor (Engine) gear will engage.
(B28): This sensor is located on the right side of the
transmission and monitors torque converter input shaft
speed.
Continued on next page TX,15,111797 –19–10MAR99–2/3

092005
PN=201
If the machine is in fourth gear and going downhill, it If the machine is operating faster than 20% greater
will automatically shift up to fourth gear as ground than wide open throttle in the gear engaged, a
speed dictates, regardless of engine speed downshift or reversal will not be permitted.
TX,15,111797 –19–10MAR99–3/3
Transmission Modes Of Operation—Manual And Automatic (S.N. —590067)
NOTE: See Monitor Display Unit—Accessory Menu The machine will automatically select 2nd, 3rd, or 4th
(S.N. —590067) for more detailed instructions gear according to the machine ground speed. The
on scrolling through menus and modes. following rules apply:
(Group 9015A-15.)
1. When shifting from Neutral to any forward gear
The transmission has two basic modes of operation: (automatic), the transmission controller will engage
9015A Manual Mode and Automatic Mode. the gear appropriate for the ground speed.
15 2. The transmission will shift based on transmission
58 Manual Mode load and ground speed. If the machine is
accelerated in the gear engaged, then the
The shifter is in 1st, 2nd, 3rd, or 4th gear. The transmission will up shift. If the machine is
following rules apply: decelerated in the gear engaged, then the
transmission will down shift.
1. When shifting from neutral to 1st, 2nd, 3rd, 4th 3. If selector is in fourth gear and going downhill,
Forward or Reverse, the selected gear will be machine will automatically shift up to fourth gear as
immediately engaged. ground speed dictates, regardless of engine speed.
2. When shifting from 1st to 3rd in the same direction, 4. Reversals will be controlled by checking the ground
the transmission controller will shift from 1st to 2nd, speed against the allowed reversal speed set in the
and then to 3rd. transmission controller.
3. If 3rd or 4th gear is engaged in either direction with 5. If 2nd gear is engaged and shifter switch is moved
the machine moving accordingly and a direction to Reverse position, the machine will reverse
change is made, the machine will automatically shift immediately. However, if a 3rd to 2nd automatic
down to 2nd gear incrementally and then change shift has already been started, the transmission
direction. The machine will then shift back up controller will complete that automatic downshift
incrementally. first, before changing to reverse direction.
6. If 3rd or 4th gear is engaged and shifter switch is
Automatic Mode moved to Reverse position, the machine will
automatically shift down to 2nd gear Forward and
The Auto Transmission Switch (S6) in the side console than into 2nd gear reverse direction.
must be turned to the On position, sending a signal to
pin 29 of the transmission controller.
TX,15,111201 –19–31AUG96–1/1

092005
PN=202
Transmission Functions Set At Monitor Display Unit (S.N. —590067)
NOTE: See Monitor Display Unit—Accessory Menu position of the brake pedal linkage by the voltage
(S.N. —590067) for more detailed instructions reading. When it senses voltage higher than the
on scrolling through menus and modes. medium voltage set point, the transmission will
(Group 9015A-15.) “disengage” (release clutch) and modulate to neutral.
In this position the machine will still roll slightly.
Clutch Cut-Off
The Clutch Cut-Off function can be set at the monitor clutch) and modulate into the appropriate gear (based
display unit in the Accessory menu. In the Clutch on ground speed) if the Clutch Cut-Off Sensor (B33)
Cut-Off mode of operation, there are three different voltage reaches the engagement set point. This
settings to choose from: voltage is lower than the clutch cut-off set point.
• Level Ground The transmission will also reengage if the clutch cut-off
• Small Slope enable switch is turned to the Off position.
9015A
• Steep Slope 15
Steep Slope (A 013): When the Steep Slope function 59
By turning one of these settings On, the other two are is turned On in the monitor display unit, the Clutch
automatically turned Off. Cut-Off Enable Switch (S11) turned On, and the brake
pedal is pressed down, the Clutch Cut-Off Sensor
Level Ground (A 011): When the Level Ground (B33), which is a rotary potentiometer, will sense the
function is turned On in the monitor display unit, the position of the brake pedal linkage by the voltage
Clutch Cut-Off Enable Switch (S11) turned On, and the reading. When it senses voltage higher than the high
brake pedal is pressed down, the Clutch Cut-Off voltage set point, the transmission will “disengage”
Sensor (B33), which is a rotary potentiometer, will (release clutch) and modulate into neutral. In this
sense the position of the brake pedal linkage by the position the machine will still roll slightly.
voltage reading. When it senses voltage higher than
the low voltage set point, the transmission will In “Auto” mode, the transmission will “reengage” (apply
“disengage” (release clutch) and modulate to neutral. clutch) and modulate into the appropriate gear (based
In this position the machine will still roll slightly. on ground speed) if the Clutch Cut-Off Sensor (B33)
voltage reaches the engagement set point. This
In “Auto” mode, the transmission will “reengage” (apply voltage is lower than the clutch cut-off set point.
clutch) and modulate into the appropriate gear (based
on ground speed) if the Clutch Cut-Off Sensor (B33) The transmission will also reengage if the clutch cut-off
voltage reaches the engagement set point. This enable switch is turned to the Off position.
voltage is lower than the clutch cut-off set point.
Quick Shift
enable switch is turned to the Off position. The Quick Shift function can be set at the monitor
display unit in the Accessory menu. In the Quick Shift
Small Slope (A 012): When the Small Slope function mode of operation, there are two different functions to
is turned On in the monitor display unit, the Clutch choose from:
Cut-Off Enable Switch (S11) turned On, and the brake
pedal is pressed down, the Clutch Cut-Off Sensor • Down/Up
(B33), which is a rotary potentiometer, will sense the • Down Only

092005
PN=203
When one of them is selected and turned On, the switch when the transmission is in automatic operation,
other is automatically turned Off. the transmission will down shift to one gear below the
gear displayed in basic display window. This change is
This mode allows the operator to choose between made independent from shifter switch selection.
Down/Up and Down Only shift functions when the
transmission is in manual or automatic operation. Down Only works basically the same in automatic as
in manual, with the following exception.
Down/Up: When this function is turned On, the
transmission will down shift one gear when the Quick Once a downshift is made by pressing the quick shift
Shift Switch (S7) (at top of pilot controller handle) is switch, the transmission will shift up again (if ground
pressed down once. It is not possible to down shift speed and/or load requires it). For example, if
more than one gear. downshift is made from third to second, it will
automatically shift up again to second, but no higher
When the quick shift switch is pressed down again, the than second.
transmission will electronically shift up one gear again.
Auto Mode To First
9015A
15 Down Only—Transmission in Manual Operation:
60 When this function is turned On, each time the Quick In the monitor display unit menu, select Auto Mode to
Shift Switch (S7) (at top of pilot controller handle) is First (A 03) to turn it On.
pressed down, the transmission will shift down one
gear (regardless of selected gear). With the transmission running in Automatic Mode and
the Auto Mode to First turned on in the monitor display
If the operator presses down on the quick shift switch unit, the transmission will automatically shift to 1st gear
while no shift is taking place, the controller will cause under two conditions:
the transmission to shift down one gear (regardless of
selected gear).
NOTE: The directional lever has to remain in neutral
If the operator presses down on the quick shift switch for a predetermined amount of time before the
while an up shift is taking place, the transmission transmission will start out in 1st gear. The
controller will cause the transmission to shift down to transmission will not shift to 1st gear when
the previous gear. making reversals and the directional lever
passes through neutral. If there is a high load
If the operator presses down on the quick shift switch on a direction change (high speed, full throttle,
while a down shift is taking place, the transmission and possibly a load in the bucket) the
controller will ignore the request for the down shift. transmission will downshift to 1st.
Once a down shift is made by pressing the quick shift • When shifting out of neutral to either forward or
switch, the transmission will not shift up again unless a reverse, the transmission will start out in 1st gear
direction or gear change is made. • If the machine is running in 2nd gear and a high
load is encountered, the transmission will
Down Only—Transmission in Automatic automatically shift to 1st gear.
Operation:If the operator presses the quick shift

092005
PN=204
When the gear selector is shifted out of neutral to the transmission will automatically shift to 1st gear.
either forward or reverse, the transmission will start in The transmission will stay in 1st gear until ground
1st gear. As ground speed increases the transmission speed increases. As ground speed increases, the
will up-shift to 2nd gear. The transmission will now transmission will up-shift to 2nd gear. The transmission
operate automatically between gears 2 through 4 in will now operate automatically in gears 2 through 4 in
forward and 2 through 3 in reverse, depending on the forward and 2 through 3 in reverse depending upon
position of the speed selector. Once the transmission the position of the speed selector.
shifts out of 1st gear it will not automatically shift into
1st gear again, unless the machine is under a high Once the transmission shifts out of 1st gear it will not
load. automatically shift into 1st gear again, unless, the
machine detects another high load condition.
When the transmission is running in 2nd gear and a
high load is encountered, (such as loading the bucket)
9015A
15
61
TX,15,111748 –19–10MAR99–3/3

092005
PN=205
Transmission Shift Ranges In Automatic

Mode (S.N. —590067)
The following charts show the response of the

transmission in automatic mode when the quick shift
switch on the pilot controller lever is pushed down.
Down/Up (Quickshift)—Transmission in Automatic Mode

Auto Mode to First Enabled by the Operator
*Transmission has not shifted to the higher range due to low ground speed.
— Refers to all gears in between (i.e. 4F—1F is the same as 4F, 3F, 2F and 1F)
Gear Selector Position Actual* Working Range After first push of button After second push of
button
1F(A) 1F(A) 1F no change 1F(A)
2F(A) 1F(A) 1F 1F 2F(A) speed depend 2F—
9015A 1F
15
62 2F(A) 2F(A) 2F—1F 1F 2F(A) speed depend 2F—
1F
1F
3F(A) 2F(A) 2F—1F 1F 3F(A) speed depend 3F—
1F
3F(A) 3F(A) 3F—1F 2F—1F 3F(A) speed depend 3F—
1F
1F
1F
1F
1F

092005
PN=206
Down/Up (Quickshift)—Transmission in Automatic Mode

Auto Mode to First Not Enabled By the Operator
*Transmission has not shifted to the higher range due to low ground speed
—Refers to all gears in between (i.e. 4F— is the same as 4F, 3F, 2F and 1F)
Gear Selector Position Actual* Working Range After first push of button After second push of
button
2F(A) 2F(A) 2F 1F 2F(A) speed depend 2F
2F
2F
2F
2F
4F(A) 4F(A) 4F—2F 3F—2F 4F(A) speed depend 4F— 9015A
2F 15
63
Down Only (Quickshift)—Transmission in Automatic Mode

Auto Mode to First Enabled by the Operator
—Refers to all gears in between (i.e. 4F—1F is the same as 4F, 3F, 2F and 1F)
Gear Selector Actual* Working Range After first push of After second push of After third push of
Position button button button
1F(A) 1F(A) 1F no change no change no change
2F(A) 2F(A) 2F—1F 1F no change no change
3F(A) 3F(A) 3F—1F 2F—1F 1F no change
4F(A) 3F(A) 3F—1F 2F—1F 1F no change
4F(A) 4F(A) 4F—1F 3F—1F 2F—1F 1F

092005
PN=207
Down Only (Quickshift)—Transmission in Automatic Mode

Auto Mode to First Not Enabled by the Operator
<Refers to all gears in between (i.e. 4F— 1F is the same as 4F, 3F, 2F and 1F)
Gear Selector Actual* Working Range After first push of After second push of After third push of
Position button button button
2F(A) 2F(A) 21F 1F no change no change
3F(A) 3F(A) 3F—2F 2F 1F no change
4F(A) 3F(A) 3F—2F 2F 1F no change
4F(A) 4F(A) 4F—2F 3F—2F 2F 1F
9015A
15
64
TX,15,111203 –19–30AUG96–3/3

092005
PN=208
Transmission Control Unit Response To Malfunctions (S.N. —590067)
The Transmission Control Unit (TCU) will change transmission will allow only one gear in each direction.
machine operation depending on the malfunction in the In some cases only one direction may be possible.
transmission circuit. Below are these different
operations and component which will cause them. Output Speed Less Than Transmission Control
Unit Programmed Value— Slippage is measured in
Some of these component will also generate a clutch pack engagement, and damage to transmission
Diagnostic Trouble Code (DTC) when they can occur.
malfunction. See Transmission Diagnostic Trouble
Codes (S.N. —590067) for more information. (Group At the first occurrence of this failure, the transmission
9015A-20.) control unit will shift the transmission to Neutral. The
operator must then shift the control lever to Neutral,
Normal Operation then to Forward or Reverse to get the machine to
move in “Limp Home” mode of 2nd gear. The basic
In the Normal mode, following conditions exist: display window of monitor display unit will show the
9015A
gear as FF for Forward and FR for Reverse. Service 15
• No transmission “Service Light” on codes will be available for viewing in (d) diagnostic 65
• No failure detected in the transmission system or menu of the monitor display unit.
• If there is a failure detected, it has no effect or slight
effect on transmission control Output Speed More than TCU Programmed Value—
• Transmission control unit will work primarily without Sensor is failed or there is over speeding of
limitation; in special cases with minimal limitations transmission due to ground or engine speed. The
(Also see Transmission Control Unit Response to transmission will shift to Neutral.
Malfunctions, this group.)
The operator must then stop the machine and shift
Substitute Clutch Control Operation control lever to Neutral before shifting machine into
Forward or Reverse “Limp Home” 2nd gear. The basic
In the Substitute Clutch Control mode, following display window of the monitor display unit will show
conditions exist: the gear as FF for Forward or FR for Reverse. The
transmission service light will be On and service codes
• Transmission can not change the gears or the will be available for viewing in (d) diagnostic menu of
direction under the control of the normal clutch the monitor display unit.
programmed modulation.
• One of the speed sensors has failed or is Transmission Shutdown:
disconnected.
• Transmission controller unit will default to a “Timed Severe Failure That Disables Control of
Shift” for clutch pack engagement. All shift Transmission—The TCU will shut off the solenoid
modulations are only time controlled. valves in the control valve for the clutches and the
common power supply. The transmission will shift to
Limp Home Operation Neutral and the park brake will be disengaged. The
operator will have to stop the machine with service
When the transmission control unit detects a failure in brakes and machine will not shift into a “Limp Home”
the system that affects transmission control, the mode.

092005
PN=209
Severe Failure That Disables Control of System— will be engaged and the transmission will remain in
The TCU will shut off all solenoids in the control valve Neutral. No “Limp Home” mode will be available.
and also both common power supplies. The park brake
DETECTED MALFUNCTION TCU RESPONSE OPERATION MODE

Malfunction of Shifter Switch (S10) (Direction TCU Shifts Transmission to Neutral Transmission Shutdown
Select Signal)
Malfunction of Shifter Switch (S10) (Gear The Malfunction Cannot be Detected in Normal
Range Signal) Systems with DW2 Gear Selector
Malfunction Clutch Cut-Off Input Clutch Cut-Off not Possible Normal
Malfunction Park Brake System TCU Shifts Transmission to Neutral Transmission Shutdown
Malfunction Engine Speed Input Clutch Modulation Fixed Time (Nominal), Substitute Clutch Control
Engine Overspeed Protection Operates With
Turbine Speed Input
Malfunction Turbine Speed Input Clutch Modulation Fixed Time (Nominal) Substitute Clutch Control
Backup Clutch Modulation
9015A
15 Malfunction Internal Speed Input Clutch Modulation Time Controlled Substitute Clutch Control
66 Malfunction Output Speed Input Clutch Modulation Time Controlled, Mode for Substitute Clutch Control
Output Speed Sensor Failure
Malfunction Temperature Sensor Input Replacement Value for Temperature 80° C Normal
(176° F)
Malfunction Low/High Power at Battery TCU Will Shut Off All Valve Solenoids, TCU Shutdown
Transmission to Neutral
Malfunction Back-Up Alarm Relay (K10), No Response Normal
Short to Ground

092005
PN=210
DETECTED MALFUNCTION TCU RESPONSE OPERATION MODE

Failure Park Brake Release Solenoid (Y19) Park Brake Engaged by Shut Off of Power Machine Not Moveable
Short Circuit to Ground Supply
Open Circuit, Short Circuit to Battery TCU Shifts Transmission to Neutral Transmission Shutdown
Malfunction Clutch C1 Solenoid (Y3), Short TCU Will Shift One Gear (Selected Gear Limp Home
Circuit to Ground, Open Circuit, Short Circuit Depends on Clutch Failure)
to Battery
to Battery
to Battery
Malfunction High-Range Clutch Solenoid TCU Will Shift One Gear (Selected Gear Limp Home
(Y1), Short Circuit to Ground, Open Circuit, Depends on Clutch Failure)
Short Circuit to Battery
Malfunction Low-Range Clutch Solenoid (Y5) TCU Will Shift One Gear (Selected Gear Limp Home 9015A
Short Circuit to Ground, Open Circuit, Short Depends on Clutch Failure) 15
Circuit to Battery 67
Malfunction Reverse Clutch Solenoid (Y2), Only One Direction Possible, TCU Will Shift Limp Home
Short Circuit to Ground, Open Circuit, Short One Gear (Selected Gear Depends on
Circuit to Battery Clutch Failure)
More Than One Malfunction, Short Circuit to TCU Shifts Transmission to Neutral Transmission Shutdown
Ground at Clutch Solenoids
Malfunction at Communication on CAN TCU Will Shut Off All Valve Solenoids, TCU Shutdown
Transmission to Neutral
TX,15,111261 –19–21SEP02–3/3
Park Brake Circuit Theory Of Operation

(S.N. —590067)
(S.N. —590067)

092005
PN=211
T110621 –19–23JUL97

092005
PN=212
9015A-15-68 - A 9015A-15-68 - B
T110621 –19–2
TM2075 (03
9015A-15-68 - A
–19–23JUL97

092005
PN=212
9015A-15-68 - B
NOTE: These circuits work in conjunction with the The monitor display unit then determines the
Transmission Control Unit (A3). appropriate warning level, based on park brake
pressure switch status and the “in gear” or “neutral”
Back-Up Alarm status. If the machine is in “neutral,” the park brake
indicator light will come on. If the machine is “in gear”
Power flows from the Park Brake and Back Up Alarm the park brake indicator light and red STOP slight will
5 A Fuse (F13) to energize the Back Up Alarm Relay flash.
(K10). When the Shifter Switch (S10) is moved to the
Reverse position, the relay is grounded through the The park brake pressure switch will open when brake
Transmission Controller (pin 7) and power flows to the pressure is above 1 241 ± 69 kPa (12 ± 0.7 bar) (180
Back Up Alarm (H3) (and Back Up Light (E1) on ± 10 psi), and the park brake releases. The light in the
Hitachi machines.) monitor display unit will be turned off.
Park Brake Sensing Circuit Specification

Park Brake Pressure Switch
Opens When Brake Pressure is
NOTE: The Park Brake Pressure Switch (B34) senses Above—Pressure ...................................................... 1172—1310 kPa 9015A
hydraulic brake pressure but does not directly 11.7—13.1 bar 15
indicate the status of the Park Brake Release 170—190 psi 69
Switch (S8). This circuit functions in any gear
selection. Park Brake Release Circuit
The park brake pressure switch (B34) is a normally The Park Brake Release Rocker Switch (S8) has three
closed switch, which is powered by the Secondary positions:
Steering, Park Brake and Service Brake Pressure
Switches 5 A Fuse (F10). • Park Brake On, Detented Position
• Neutral, Center Detented Position
The switch closes when brake pressure is below 1 034 • Park Brake Release, Momentary Position
± 103 kPa (10 ± 1 bar) (150 ± 15 psi). When the
switch is closed, the park brake is applied and the To release the park brake, Park Brake Release Switch
indicator light in the monitor display unit is on. A signal (S8) must be moved to the Park Brake Release
is sent to Chassis Control Unit (pin X3, of 60-pin Momentary position, then to the Neutral, Center
connector). Then a signal is sent from the Chassis Detented position. The switch will send a signal to the
Control Unit by way of the Controller Area Network Transmission Controller (pins 31 and 21). If engine
(CAN) link, to the monitor display unit. rpm is greater than 50 rpm, the Torque Converter
Input Speed Sensor (B28) sends a signal to the
Specification Transmission Control Unit (A3) (pins 3 and 19). The
Park Brake Pressure Switch controller then sends a signal to energize the Park
Closes When Brake Pressure is
Below—Pressure ........................................................ 931—1137 kPa
Brake Release Solenoid (Y19) and allows hydraulic
9—11 bar release of the park brake.
135—165 psi
If the Transmission Control Unit does not sense engine
The shifter switch (S10) sends an “in gear” or “neutral” rpm, it will not release the park brake. If rpm is
message to the transmission controller. The displayed on the Monitor Display Unit (MDU), the
transmission controller sends this message to the torque converter input sensor is working.
monitor display unit by way of the CAN link.

092005
PN=213
To apply the park brake, park brake switch must be If the engine stops with the key switch On, park brake
moved from the Neutral, Center Detented position to applies when following conditions exist:
the Park Brake On, detented position. The
Transmission Controller will send a signal to • Engine speed lower than 50 rpm (dead engine)
de-energize the Park Brake Release Solenoid and the • Ground speed less than 0.5 km/hr (0.31 mph)
park brake will apply.
The park brake also applies when the key switch is in

the Off position.
TX,9015,111928 –19–20SEP02–4/4
9015A
15
70

092005
PN=214
Pilot Enable And Boom Down Circuit Theory Of Operation (S.N. —590067)
9015A
15
71
–19–28JAN97
T106269
Continued on next page TX,15,111213 –19–11JUL00–1/2

092005
PN=215
This circuit allows the operator to lower the boom with A pilot enable/boom down 1 A diode (V9) functions to
the engine off. limit the voltage spike back to the switch contacts
when the solenoids are energized and de-energized.
The pilot enable/boom down switch (S18) has two
positions: On and Momentary Boom Lower. When the pilot enable/boom down switch (S18) is
powered in the On position, the BHKO and RTD 5 A
Pilot Enable/Boom Down Switch "On" Position: fuse (F15) is also powered.
The key switch must be in On, Bulb Check, or Start Pilot Enable/Boom Down Switch "Momentary Boom
position and the engine running. The Chassis Control Lower" Position:
Unit (A2) (pin C3 of 30-pin connector) sends a signal
to energize the detent enable relay (K32). The With the key switch in the Off position, power flows
accumulator pressure switch (B27) must be closed from the unswitched boom down, radio, and dome light
before the CCU will energize relay K32. Power from fuse (F28) to the pilot enable/boom down switch.
the energized ignition relay (K4) flows through the When the switch is in the Momentary Boom Lower
detent enable relay to the pilot enable 7.5A fuse (F16). position, power flows through the switch to energize
9015A
15 the pilot enable solenoid and the boom down solenoid.
72 From the pilot enable fuse, power flows through the A pilot enable/boom down 1 A diode functions to limit
pilot enable boom down switch to activate the boom the voltage spike back to the switch contacts when the
down solenoid (Y15) and pilot enable solenoid (Y14). solenoids are energized and de-energized.
TX,15,111213 –19–11JUL00–2/2

092005
PN=216
Return-to-Carry, Boom Height Kickout and Return-to-Dig Circuit Theory Of Operation

(S.N. —590067)
9015A
15
73
–19–17OCT02
T159429
Continued on next page TX17994,0000349 –19–21SEP02–1/2

092005
PN=217
The return-to-carry, boom height kickout and bucket will be in the dig position. The detent can be
return-to-dig circuits are powered through the pilot manually released by moving the control lever to the
enable/boom down switch (S18) when the engine is center.
running. When S18 is Off, these circuits will not be
powered. See Return-to-Dig Adjustment (S.N. —590067) to
adjust return-to-dig position. (Group 9015A-20.)
Float Position
Boom Height Kickout and Return-to-Carry
The float electromagnetic detent coil is powered
whenever the engine is running and the return-to-carry Both boom height kickout and return-to-carry are
enable switch (S15) is Off. With pilot controller (A4) controlled by the Chassis Control Unit (CCU). The
lever is pushed fully forward the detent coil will hold operator sets these positions using the Boom Height
the lever in that position and boom will float. It can be Kickout Switch (S16) and Return-to-Carry Switch
manually disengaged by pulling back on the control (S15).
lever.
The CCU receives a signal from the Boom Position
9015A
15 Return-to-Dig Sensor (B9). This sensor varies voltage based on
74 boom position, which the CCU uses to determine
The return-to-dig switch (B22) closes when it senses a boom position. The CCU stores the voltage output
metal object passing in front of it. The dig position is from this sensor when the operators sets height and
determined by the location of the metal actuator bar carry kickout positions. These voltage value will be
connected to the bucket linkage. stored until the operator resets them.
The return-to-dig detent coil in the pilot controller is When the pilot controller is moved to the full boom
powered when the bucket is below the dig position raise or lower position, detent magnets in the pilot
(actuator bar is in front of sensor). If the pilot controller control will hold the lever until to boom reaches the
lever is pulled fully to the bucket rollback position, the position set by the operator. The CCU will de-energize
return-to-dig detent will hold the lever in that position. detent coil, the pilot controller will return to center
The bucket will move until the actuator bar passes by position, and the boom will stop in the set positions.
the return-to-dig switch. The return-to-dig switch (B22)
will open and de-energize Return-to-Dig Relay (K13). See Boom Height Kickout Adjustment (S.N. —590067)
This will de-energize the return-to-dig detent coil, and or Return-To-Carry Kickout Adjustment (S.N. —
the pilot controller will return to the center position. The 590067) for adjustment procedures. (Group 9015A-20.)
TX17994,0000349 –19–21SEP02–2/2

092005
PN=218
Secondary Steering Circuit Theory Of Operation (S.N. —590067)
9015A
15
75
–19–24FEB98
T113680

092005
PN=219
With the key switch in the ACC or On position power The Chassis Control Unit will then send a signal (pin
flows through the energized Accessory Relay #2 to the D2 of the 30-pin connector) to energize the secondary
Secondary Steering, Park Brake and Service Brake steering relay. Power flows through the Converter,
Pressure Switches 5 A Fuse. Secondary Steering and Start Aid 7.5A Fuse, through
the secondary steering relay to energize a relay in the
The secondary steering pressure switch is closed secondary steering pump motor. Battery power is then
when the steering pressure is normal. When the sent to the pump motor from the starter motor, and the
steering pressure is lower than 240 kPa (2.4 bar) (35 pump motor will operate.
psi), the switch will open and send a signal to the
chassis control unit (pin X2 of the 60-pin connector).
CED,TX17864,74 –19–01APR98–2/2
9015A
15
76

092005
PN=220
Engine Control Unit Circuit Theory Of Operation (S.N. —590067)

T159427 –19–17OCT02
CED,TX17864,78 –19–29OCT02–1/3

092005
PN=221
9015A-15-77 - A 9015A-15-77 - B 9015A-15-77 - C
Engine Control Unit Circuit Theory Of Operation (S.N. —590067)

T159427 –19–17OCT02
CED,TX17864,78 –19
TM2075 (03MAR05) 9015A-15-77 644J and 72
9015A-15-77 - A
8 –19–29OCT02–1/3
nd 724J Loader
092005
PN=221
9015A-15-77 - B
9015A-15-77 - C
9015A-15-77 - Blank
See Electronic Control System Terminology for engine Fuel Temperature Sensor (B6)
sensor definitions. (CTM 255.)
Engine control unit uses the fuel temperature sensor
The engine control unit (ECU) (A1) converts analog (B6) to calculate fuel density and adjust fuel delivery
voltage signals from various sensors into digital signals accordingly.
the central processing unit can understand.
For information on sensor testing, see Engine Control
The central processing unit performs computations to Unit Temperature Sensors Test (S.N. —590067).
control injection fuel quantity and injection timing. It (Group 9015A-20.)
communicates the desired fuel quantity and timing to
the high pressure fuel pump and electronic injectors. Water In Fuel Sensor (B48)
See Electronic Control System Operation. (CTM255.)
Water In Fuel Sensor (B48) sends a signal to engine
The ECU controls engine speed according to position control unit when water is detected in the fuel.
of Throttle Position Sensor (B14) attached to the
accelerator pedal. This signal is sent to the ECU from See Water In Fuel (WIF) Sensor theory for more
9015A
15 the Chassis Control Unit (CCU) over the CAN. information. (CTM225.)
78
Coolant Sensor (B1) Fuel Rail Pressure Sensor (B49)
Coolant overheat sensor (B1) is a temperature Fuel Rail Pressure Sensor (B49) controls the amount
sensitive variable resistor. ECU sends 5 volts to the and timing of fuel transferred from the high pressure
sensor, monitors voltage drop across the sensor and fuel pump.
compares voltage drop to preprogrammed values to
determine temperature. See Measuring Pressure for theory on all engine
pressure sensors for more information. (CTM255.)
Unit Temperature Sensors Test (S.N. —590067). For information on sensor testing, see Engine Control
(Group 9015A-20.) Unit Pressure Sensors and Solenoids Test (S.N. —
590067). (Group 9015A-20.)
Manifold Air Temperature Sensor (B5)
Engine Crank Speed Sensor (B4)
See Measuring Temperature. (CTM255.)
Engine Crank Speed Sensor (B4) is an inductive type
Manifold air temperature sensor (B5) is a temperature pickup sensor that detects teeth on the timing wheel.
sensitive voltage resistor. ECU sends 5 volts to the ECU uses the crank position input to determine engine
sensor, monitors voltage drop across the sensor and speed and precise piston position in relation to firing
compares voltage drop to preprogrammed values to order. The crank timing wheel is composed of evenly
determine temperature. ECU uses this sensor to spaced teeth, with two ground off. The ground teeth
monitor manifold air temperature. help the ECU determine when cylinder #1 is at
top-dead-center.
Unit Temperature Sensors Test (S.N. —590067). See Measuring Engine Speed theory on all engine
(Group 9015A-20.) speed sensors for more information. (CTM225.)
Continued on next page CED,TX17864,78 –19–29OCT02–2/3

092005
PN=222
For information on sensor testing, see Engine Control signal to the solenoids to regulate delivery of fuel to
Unit Speed Sensors Test (S.N. —590067). (Group the high pressure common rail. When the solenoids
9015A-20.) are energized, fuel is discharged from the high
pressure fuel pump to the high pressure common rail.
Engine Cam Speed Sensor (B5)
See Pump Control Valves (PCVs) theory for more
Engine Cam Speed Sensor (B5) is an inductive type information. (CTM255, Group 140.)
pickup sensor that detects notches on the auxiliary
gear of the high pressure fuel pump camshaft. The For information on solenoid testing, see Engine Control
auxiliary gear is composed of evenly spaced notches Unit Pressure Sensors and Solenoids Test (S.N. —
with one additional notch offset to tell the ECU that 590067). (Group 9015A-20).
cylinder #1 is approaching top-dead-center.
Electronic Fuel Injectors (Y11—Y16)
See Measuring Engine Speed theory on all engine
speed sensors for more information. (CTM225.) ECU controls start of injection and amount of fuel
injected by energizing and de-energizing the two-way
9015A
For information on sensor testing, see Engine Control valve on the injectors. For additional information, see 15
Unit Speed Sensors Test (S.N. —590067). (Group Electronic Injector (EI) Operation. (CTM255.) 79
9015A-20.)
High Pressure Fuel Pump (Solenoid 1) (Y8) and

High Pressure Fuel Pump (Solenoid 2) (Y9)
Solenoids (Y8 and Y9) are located on the high

pressure fuel pump. The ECU sends an electronic
CED,TX17864,78 –19–29OCT02–3/3

092005
PN=223
9015A
15
80

092005
PN=224
Group 20
References
Alternators And Starting Motors—Use CTM77

(S.N. —590067)
For additional information, the component technical

manual (CTM) is also required.
Use the CTM in conjunction with this machine manual.
–UN–17JAN89
TS225
TX,20,111114 –19–04SEP96–1/1
9015A
20
1

092005
PN=225
References
Diagnostic Trouble Codes Quick Reference List (S.N. —590067)
To check codes, See Diagnostic Trouble Codes (DTC) • See F0353 FWD High Range Clutch Pack Solenoid
(S.N. —590067). (Group 9005-10) Open
• See F0354 FWD High Range Clutch Pack Solenoid
CCU SERVICE CODES Short to Ground
• See F0355 FWD High Range Clutch Pack Solenoid
• See F0275 CCU Power Dissipation Excessive Short to Power
• See F0356 Third Speed Clutch Pack Solenoid Open
TRANSMISSION SYSTEM CODES: • See F0357 Third Speed Clutch Pack Solenoid
Short-to-Ground
• See F0300 Oil Temperature High Long • See F0358 Third Speed Clutch Pack Solenoid
• See F0305 TCU Output Speed Zero Short-to-Power
• See F0306 TCU Voltage Low • See F0359 Second Speed Clutch Pack Solenoid
• See F0307 TCU Voltage High Open
• See F0308 TCU Valve Solenoid Power • See F0360 Second Speed Clutch Pack Solenoid
9015A
20 • See F0309 TCU Park Brake Solenoid Power Short-to-Ground
2 • See F0315 Oil Filter Circuit Short-to-Power • See F0361 Second Speed Clutch Pack Solenoid
• See F0320 1st Gear Clutch Slippage Short-to-Power
• See F0321 2nd Gear Clutch Slippage • See F0362 First Speed Clutch Pack Solenoid Open
• See F0322 3rd Gear Clutch Slippage • See F0363 First Speed Clutch Pack Solenoid
• See F0323 4th Gear Clutch Slippage Short-to-Ground
• See F0324 Forward Gear Clutch Slippage • See F0364 First Speed Clutch Pack Solenoid
• See F0325 Reverse Gear Clutch Slippage Short-to-Power
• See F0330 Clutch Cut-Off Circuit Voltage Low • See F0365 Reverse Clutch Pack Solenoid Open
• See F0331 Clutch Cut-Off Circuit Voltage High • See F0366 Reverse Clutch Pack Solenoid
• See F0336 TCU Configuration Bad Short-to-Ground
• See F0337 TCU Memory Bad • See F0367 Reverse Clutch Pack Solenoid
• See F0339 Temperature Sensor Voltage Short-to-Power
Short-to-Ground • See F0368 FWD Low Range Clutch Pack Solenoid
• See F0340 Temperature Sensor Voltage Open
Short-to-Power • See F0369 FWD Low Range Clutch Pack Solenoid
• See F0341 Output Speed Signal Bad Short-to-Ground
• See F0342 Output Speed Circuit Short-to-Ground • See F0370 FWD Low Range Clutch Pack Solenoid
• See F0343 Output Speed Circuit Short-to-Power Short-to-Power
• See F0344 Internal Clutch Speed Signal Bad • See F0375 Gear Selector
• See F0345 Internal Clutch Speed Circuit • See F0377 Oil Temperature Circuit Short-to-Power
Short-to-Ground • See F0378 Oil Temperature Circuit Open
• See F0346 Internal Clutch Speed Circuit • See F0379 FNR Selector Switch Open
Short-to-Power • See F0380 Oil Filter Restricted
• See F0347 Turbine Speed Signal Bad • See F0384 Reverse Alarm Relay Short-to-Power
• See F0348 Turbine Speed Circuit Short-to-Ground • See F0385 Reverse Alarm Relay Short-to-Ground
• See F0349 Turbine Speed Circuit Short-to-Power • See F0386 Reverse Alarm Relay Open
• See F0350 Input Speed Signal Bad • See F0387 Park Brake Solenoid Short-to-Power
• See F0351 Input Speed Circuit Short-to-Ground • See F0388 Park Brake Solenoid Short-to-Ground
• See F0352 Input Speed Circuit Short-to-Power • See F0389 Park Brake Solenoid Open

092005
PN=226
References
• See F0396 Oil Temperature High • See F0444 Pump Position Sensor Input Noise
(000636.02)
NOTE: Some engine codes are listed more than once. • See F0444 Pump Position Sensor Input Pattern
Access codes with Service ADVISOR to Error (000636.10)
determine SPN.FMI number. If using monitor • See F0445 Crank Position/Pump Position Timing
both diagnostic procedure should be followed. Moderately Out of Sync
• See F0450 Fuel Rail Pressure Input Voltage High
ENGINE SYSTEM CODES: • See F0451 Fuel Rail Pressure Input Voltage Low
• See F0453 Water in Fuel Signal Voltage High
• See F0400 Oil Pressure Low Long • See F0454 Water in Fuel Signal Voltage Low
• See F0415 CCU Throttle Circuit Voltage Low • See F0455 Manifold Air Temperature Moderately
• See F0416 CCU Throttle Circuit Voltage High High
• See F0423 Ambient Air Temperature Input Voltage • See F0456 Pump Control Valve #2 Fuel Flow Not
High Detected
• See F0424 Ambient Air Temperature Input Voltage • See F0469 Pump Control Valve #1 Fuel Flow Not
Low Detected
9015A
• See F0425 Engine Coolant Temperature Input • See F0470 Fuel Rail Pressure Control Error 20
Voltage High • See F0471 Fuel Rail Pressure Sensor Supply 3
• See F0426 Engine Coolant Temperature Input Voltage Low
Voltage Low • See F0478 Engine Oil Pressure Circuit Voltage Low
• See F0431 Cylinder #1 EI Circuit Open (000651.05) • See F0479 Engine Oil Pressure Circuit Voltage High
• See F0431 Cylinder #1 EI Circuit Shorted • See F0485 Water in Fuel Detected
(000651.06) • See F0499 Engine Oil Pressure Low
• See F0432 Cylinder #2 EI Circuit Open (000652.05) • See F0500 Engine Coolant Temperature High Long
• See F0432 Cylinder #2 EI Circuit Shorted • See F0515 Engine Air Filter Restriction Circuit
(000652.06) • See F0516 Engine Fuel Level Circuit Voltage Low
• See F0433 Cylinder #3 EI Circuit Open (000653.05) • See F0517 Engine Fuel Level Circuit Open
• See F0433 Cylinder #3 EI Circuit Shorted • See F0576 Engine Coolant Temperature Circuit
(000653.06) Noisy
• See F0434 Cylinder #4 EI Circuit Open (000654.05) • See F0577 Engine Coolant Temperature Circuit
• See F0434 Cylinder #4 EI Circuit Shorted Short-to-Ground
(000654.06) • See F0578 Engine Coolant Temperature Circuit
• See F0435 Cylinder #5 EI Circuit Open (000655.05) Open
• See F0435 Cylinder #5 EI Circuit Shorted • See F0580 Engine Air Filter Restricted
(000655.06) • See F0599 Engine Coolant Temperature High
• See F0436 Cylinder #6 EI Circuit Open (000656.05)
• See F0436 Cylinder #6 EI Circuit Shorted STEERING SYSTEM CODES:
(000656.06)
• See F0437 Fuel Temperature Input Voltage High • See F0998 Steering Pressure Circuit
• See F0438 Fuel Temperature Input Voltage Too Low • See F0999 Steering Pressure Low
• See F0439 Pump Control Valve #1 Error
• See F0440 Pump Control Valve #2 Error BRAKE SYSTEM CODES:
• See F0441 Crank Position Input Missing
• See F0442 Crank Position Input Noise • See F1097 Service Brake Pressure Circuit
• See F0442 Crank Position Input Pattern Error • See F1099 Service Brake Pressure Low
• See F0443 Pump Position Sensor Input Missing

092005
PN=227
References
ELECTRICAL SYSTEM CODES: • See F1664 Brake Light Pressure Circuit

• See F1665 Drive Light Switch Circuit
• See F1620 CCU Spare Relay #1 Short • See F1667 Turn Switch Circuit Short
• See F1621 CCU Spare Relay #3 Short • See F1668 Hazard Switch Circuit
• See F1622 CCU Spare Relay #4 Short • F1671 Return-to-Carry Detent Solenoid Circuit Error
• See F1623 CCU Spare Relay #5 Short • F1672 Boom Height Kickout Detent Solenoid Circuit
• See F1624 Air Preheat Driver Short Ground Error
• See F1625 Detent Enable Driver Short-to-Ground • See F1699 Config Bad
• See F1626 Ride Control Boom Driver
Short-to-Ground HYDRAULIC SYSTEM CODES:
• See F1628 Ride Control On Driver Short-to-Ground
• See F1629 Left Turn Driver Short-to-Ground • See F2100 Oil Temperature High Long
• See F1630 Right Turn Driver Short-to-Ground • See F3115 Oil Filter Restriction Circuit
• See F1633 Secondary Steering Driver Short-to-Ground
Short-to-Ground • See F3150 Oil Filter Restriction Circuit
• See F1634 Rear Wiper Driver Short-to-Ground Short-to-Power
9015A
20 • See F1635 Front Wiper Driver Short-to-Ground • See F3160 Ride Control Circuit Short-to-Power
4 • See F1636 CCU Relay Driver Overtemp • See F3161 Ride Control Auto Circuit
• See F1637 CCU Timer Reset Short-to-Ground
• F1638 Proportional Fan Drive Solenoid Circuit Error • See F3162 Ride Control On Circuit Short-to-Ground
• F1639 Reverse Fan Drive Solenoid Circuit Error • F3163 Boom Position Voltage Low
• See F1641 Drive Light Switch Circuit Open • F3164 Boom Position Sensor Voltage High
• See F1644 MDU Memory Bad • See F3171 Hydraulic Oil Pressure Circuit Voltage
• See F1645 CCU Memory Bad Low
• See F1647 Machine Odometer Bad • See F3172 Hydraulic Oil Pressure Circuit Voltage
• See F1648 Machine Hourmeter Bad High
• See F1649 CCU Hourmeter Bad • See F3173 Spin Control Mode Circuit
• See F1651 No ECU CAN Transmit • See F3174 Spin Control Enable Circuit
• See F1653 No CCU CAN Transmit Short-to-Ground
• See F1655 No TCU CAN Transmit • See F3175 Hydraulic Oil Temperature Circuit
• See F1658 Power Voltage Balance Short-to-Ground
• See F1660 Alternator Voltage High • See F3176 Hydraulic Oil Temperature Circuit Open
• See F1661 Alternator Voltage Low • See F3177 Hydraulic Oil Temperature Circuit Noisy
• See F1662 Power Voltage High • See F3199 Hydraulic Oil Temperature High
• See F1663 Power Voltage Low
CED,TX17864,29 –19–30MAR99–3/3

092005
PN=228
References
Transmission Diagnostic Trouble Codes

(S.N. —590067)
IMPORTANT: Whenever a Transmission Control Unit

(TCU), a Chassis Control Unit (CCU), or
Monitor Display Unit (MDU) is replaced,
the MDU must be reconfigured in the
Service Menu. See Monitor Display
Unit—Service Menu (S.N. —590067).
(Group 9015A-15.)

a Service Code. The term DTC conforms with
standards set by the Society of Automotive
Engineers (SAE).
9015A
References: 20
5
See System Functional Schematic (S.N. —590067).
(Group 9015A-10.)
See Transmission Control Unit Response To Malfunctions

(S.N. —590067) for machine operation during
transmission circuit malfunctions. (Group 9015A-15.)
F0275 CCU Power Dissipation CCU (A2) CCU (Replace). See Check
Excessive Controller (S.N. —590067). (Group
9015A-20.)
MDU (Reconfigure). See Monitor

Display Unit—Service Menu (S.N. —
590067). (Group 9015A-15.)
F0300 Transmission Oil Transmission Oil Type Wrong Transmission Oil Type
Temperature High Long (Check/Replace). See Transmission,
Hydraulic System, Park Brake, and
Tell-Tale Code displayed in MDU Differential Oil. (Operator’s Manual.)
“Service” menu. See Monitor
Display Unit—Service Menu
(S.N. —590067), Tell-Tale
Diagnostic Trouble Codes (S 02).
(Group 9015A-15.)
Transmission Oil Level Too High or See Check Transmission Oil Level.
Too Low (Operator’s Manual)

092005
PN=229
References
Transmission Oil Cooler Internal Transmission Oil Cooler Internal

Restriction Restriction (Check/Repair)
Transmission Oil Cooler Air Flow Transmission Oil Cooler Air Flow
Restriction Restriction (Check/Clean). See
Transmission Oil Cooler, Hydraulic
Oil Cooler, Air-to-Air Aftercooler, and
Radiator External Cleaning
Procedure. (Operator’s Manual)
Transmission Oil Temperature Transmission Oil Temperature

Sensor (B32) Short-To-Ground Sensor (B32) Short-To-Ground
(Check/Replace). See Electrical
Component Specifications (S.N. —
9015A
20 590067). (Group 9015A-20.)
6
Transmission Main Pressure Transmission Main Pressure
Regulating Valve Spring Broken Regulating Valve Spring Broken
(Check/Replace)
Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen
Plugged (Check/Clean)
Transmission Control Valve Gasket Transmission Control Valve Gasket

(Check/Replace). See Transmission
Control Valve Repair. (Repair
Manual Group 0360)
Torque Converter Relief Valve Stuck Torque Converter Relief Valve

Open (Check/Repair)
Transmission Oil Cooler Bypass Transmission Oil Cooler Bypass

Valve Stuck Open Valve Stuck Open (Check/Repair)
Transmission Oil Pump Worn Transmission Oil Pump Worn

(Check/Replace)
F0305 TCU Output Speed Zero Rocker, Restriction, Radio Switches Rocker, Restriction, Radio Switches
5 A fuse (F23) 5 A fuse (F23), Check/Replace. See
Fuse Specifications (S.N. —590067).
(Group 9015A-10.)
Transmission Output Shaft Speed Transmission Output Shaft Speed

Sensor (B31) Sensor (B31), Check/Replace. See
Electrical Component Specifications
(S.N. —590067). (Group 9015A-20.)

092005
PN=230
References
Wire M10 (Purple) Harness (W10) Transmission Harness (W10)—M10

Short-To-Power (Purple) Short-To-Power
(Check/Repair)
Wire R22 (Black) Harness (W10) Transmission Harness (W10)—R22

Short-To-Battery (Black) Short-To-Battery
(Check/Repair)
TCU (A3) TCU (Replace). See Check

Controller (S.N. —590067). (Group
9015A-20.)
F0306 TCU Voltage Low Batteries Batteries (Recharge/Replace)

9015A
Alternator Alternator (G4), Check/Repair 20
7
F0307 TCU Voltage High Batteries Batteries (Recharge/Replace)
Alternator Alternator (G4), Check/Repair
F0308 TCU Valve Solenoid Power TCU (A3) TCU (Replace) See Check Controller
(S.N. —590067). (Group 9015A-20.)
F0309 TCU Park Brake Solenoid TCU (A3) TCU (Replace) See Check Controller
Power (S.N. —590067). (Group 9015A-20.)
F0315 Transmission Oil Filter Transmission Oil Filter Restriction Transmission Oil Filter Restriction
Circuit Short-To-Power Switch (B20) Short-To-Power Switch (B20) Short-To-Power
(Check/Replace)
Wire N03 (Yellow) Harness (W10) Transmission Harness (W10) - N03

Short-To-Power (Yellow) Short-To-Power
(Check/Repair)
Wire N03 (Yellow) Harness (W3) Load Center Harness (W3) - N03
(Check/Repair)
CCU (A2) CCU (Replace). See Check

9015A-20.)

590067). (Group 9015A-15.)

092005
PN=231
References
F0320 Transmission 1st Gear Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen
Clutch Slippage Plugged (Clean)
Transmission Oil Type Wrong Transmission Oil Type

(Check/Replace). See Transmission,
Differential Oil. (Operator’s Manual.)
Transmission Control Valve Transmission Control Valve

Manual Group 0360)

9015A
20 Leaking (Replace). See Transmission Control
8 Valve Repair. (Repair Manual Group
0360)

(Check/Replace)
Transmission Control Solenoid (Y1) Transmission Control Solenoid (Y1)

Malfunction (Replace). See Transmission Control
Valve Repair. (Repair Manual Group
0360)

0360)

0360)

0360)

0360)

092005
PN=232
References

0360)
Transmission Output Speed Shaft Transmission Output Speed Shaft

Sensor (B31) Open Sensor (B31) Open (Check/Repair).
Specifications (S.N. —590067).
(Group 9015A-20.)
Wire M10 (Purple) Harness (W10) Transmission Harness (W10) - M10

Open (Purple) Open (Check/Repair)
9015A
Wire M10 (Purple) Harness (W3) Load Center Harness (W3) - M10 20
Open (Purple) Open (Check/Repair) 9
F0321 Transmission 2nd Gear Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen


Manual Group 0360)

Leaking (Replace). See Transmission Control
0360)

(Check/Replace)

0360)

092005
PN=233
References

0360)

0360)

0360)
9015A
20
10 Transmission Control Solenoid (Y5) Transmission Control Solenoid (Y5)
0360)

0360)

(Group 9015A-20.)

Wire M10 (Purple) Harness (W3) Load Center Harness (W3) - M10
F0322 Transmission 3rd Gear Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen


092005
PN=234
References

Manual Group 0360)

0360)

(Check/Replace)

9015A
Malfunction (Replace). See Transmission Control 20
Valve Repair. (Repair Manual Group 11
0360)

0360)

0360)

0360)

0360)

0360)

092005
PN=235
References

(Group 9015A-20.)

F0323 Transmission 4th Gear Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen
9015A
20
12 Transmission Oil Type Wrong Transmission Oil Type

Manual Group 0360)

0360)

(Check/Replace)

0360)

0360)

092005
PN=236
References

0360)

0360)

0360)
9015A
20
Transmission Control Solenoid (Y6) Transmission Control Solenoid (Y6) 13
0360)

(Group 9015A-20.)

F0324 Transmission Forward Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen
Gear Clutch Slippage Plugged (Clean)


Manual Group 0360)

092005
PN=237
References

0360)

(Check/Replace)

0360)

9015A
20 Malfunction (Replace). See Transmission Control
14 Valve Repair. (Repair Manual Group
0360)

0360)

0360)

0360)

0360)
Transmission Internal Clutch Speed Transmission Internal Clutch Speed

(Group 9015A-20.)

092005
PN=238
References

F0325 Transmission Reverse Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen
Gear Clutch Slippage Plugged (Clean)

9015A
Transmission Control Valve Transmission Control Valve 20
(Check/Replace). See Transmission 15
Manual Group 0360)

0360)

(Check/Replace)

0360)

0360)

0360)

0360)

092005
PN=239
References

0360)

0360)
Transmission Internal Clutch Speed Transmission Internal Clutch Speed

9015A
20 (Group 9015A-20.)
16
F0330 Transmission Clutch Clutch Cut-off Sensor (B33) Open Or Clutch Cut-off Sensor (B33)
Cut-off Circuit Voltage Low Short-To-Ground Open/Short-To-Ground
590067). (Group 9015A-20.)
Wire T20 (Blue) Harness (W3) Open Load Center Harness (W3) - T20
Or Short-To-Ground (Blue) Open or Short-To-Ground
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F0331 Transmission Clutch Clutch Cut-off Sensor (B33) Short To Clutch Cut-off Sensor (B33) Short To
Cut-off Circuit Voltage High Power Or Open Power or Open (Check/Replace).
(Group 9015A-20.)

092005
PN=240
References
Wire T20 (Blue) Harness (W3) Short Load Center Harness (W3) - T20
to Power or Open (Blue) Short-To-Power or Open
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F0336 TCU Config Bad MDU Configuration Incorrect MDU (Reconfigure). See Monitor
9015A
590067). (Group 9015A-15.) 20
17
9015A-20.)
MDU (Reconfigure)

9015A-20.)
MDU (Reconfigure)
F0337 TCU Memory Bad TCU (A3) TCU (Replace). See Check
9015A-20.)

590067). (Group 9015A-15.)
F0339 Transmission Temperature Transmission Oil Temperature Transmission Oil Temperature

Sensor Voltage Short-To- Ground Sensor (B32) Short-To-Ground Sensor (B32) Short-To-Ground
590067). (Group 9015A-20.)
Wire P23 (Red) Harness (W3) Load Center Harness (W3) - P23
Short-To-Ground (Red) Short-To-Ground
(Check/Repair)

092005
PN=241
References
Wire P23 (Red) Harness (W10) Transmission Harness (W10) - P23

(Check/Repair)
Transmission Clutch Cut-Off Sensor Transmission Clutch Cut-Off Sensor

(B33) Short-To-Ground (B33) Short-To-Ground
590067). (Group 9015A-20.)
(Check/Repair)
9015A
20 TCU (A3) TCU (Replace). See Check
18 Controller (S.N. —590067). (Group
9015A-20.)

590067). (Group 9015A-15.)
F0340 Transmission Temperature Transmission Oil Temperature Transmission Oil Temperature

Sensor Voltage Short-To- Power Sensor (B32) Short-To-Power Sensor (B32) Short-To-Power
590067). (Group 9015A-20.)
Short-To-Power (Red) Short-To-Power Check/Repair)
Wire P23 (Red) Harness (W10) Transmission Harness (W10) - P23

Short-To-Ground (Red) Short-To-Power
(Check/Repair)
F0341 Transmission Output Transmission Output Shaft Speed Transmission Output Shaft Speed
Speed Signal Bad Sensor (B31) Open Sensor (B31) Open
590067). (Group 9015A-20.)


092005
PN=242
References

9015A-20.)

590067). (Group 9015A-15.)
F0342 Transmission Output Transmission Output Shaft Speed Transmission Output Shaft Speed
Speed Circuit Short-To- Ground Sensor (B31) Short-To-Ground Sensor (B31) Short-To-Ground
590067). (Group 9015A-20.)
9015A
Wire M10 (Purple) Harness (W10) Transmission Harness (W10) - M10 20
Short-To-Ground (Purple) Short-To-Ground 19
(Check/Repair)
Short-To-Ground (Purple) Short-To-Ground
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F0343 Transmission Output F2—Start Aid, Converter and Check fuse F2. See Fuse
Speed Circuit Short-To- Power Secondary Steering 10 A Fuse Specifications (S.N. —590067).
(Group 9015A-10.)
Suspect fuse F2 only for Serial

Number (578660— )
Transmission Output Shaft Speed Transmission Output Shaft Speed

Sensor (B31) Short-To-Power Sensor (B31) Short-To-Power
590067). (Group 9015A-20.)

092005
PN=243
References

(Check/Repair). See System
Functional Schematic (S.N. —
590067). See Transmission Harness
590067).
(Check/Repair). See System
590067). See Load Center Harness
9015A
20 590067).
20
Wire P04 Red Open Check P04 Wire. See System
(W10) Component Location (S.N.
-590067).
Suspect wire P04 only for Serial

Number (578660—- )
Wire P27 Red Open Check P27 Wire. See System

-590067).
Suspect wire P27 only for Serial

Number ( —578659)

9015A-20.)

590067). (Group 9015A-15.)

092005
PN=244
References
F0344 Transmission Internal Transmission Internal Clutch Speed Transmission Internal Clutch Speed
Clutch Speed Signal Bad Sensor (B30) Open Sensor (B30) Open
590067). (Group 9015A-20.)


9015A
9015A-20.) 20
21
590067). (Group 9015A-15.)
Speed Circuit Short-To-Ground Sensor (B30) Short-To-Ground Sensor (B30) Short-To-Ground
590067). (Group 9015A-20.)

(Check/Repair)
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)

092005
PN=245
References
Speed Circuit Short-To- Power Sensor (B30) Short-To-Power Sensor (B30) Short-To-Power
590067). (Group 9015A-20.)

(Check/Repair)
(Check/Repair)
9015A
22 Controller (S.N. —590067). (Group
9015A-20.)

590067). (Group 9015A-15.)
F0347 Transmission Turbine Torque Converter Output Speed Torque Converter Output Speed
Speed Signal Bad Sensor (B29) Open Sensor (B29) Open
590067). (Group 9015A-20.)
Torque Converter Output Speed Torque Converter Output Speed

Sensor (B29) Loose Sensor (B29) Open
590067). (Group 9015A-20.)


9015A-20.)

092005
PN=246
References

590067). (Group 9015A-15.)
Speed Short-To-Ground Sensor (B29) Short-To-Ground Sensor (B29) Short-To-Ground
590067). (Group 9015A-20.)

(Check/Repair)
9015A
Wire M08 (Purple) Harness (W3) Load Center Harness (W3) - M08 20
Short-To-Ground (Purple) Short-To-Ground 23
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
Speed Short-To- Power Sensor (B29) Short-To-Power Sensor (B29) Short-To-Power
590067). (Group 9015A-20.)

(Check/Repair)
(Check/Repair)

9015A-20.)

092005
PN=247
References

590067). (Group 9015A-15.)
F0350 Transmission Input Speed Torque Converter Input Speed Torque Converter Input Speed
Signal Bad Sensor (B28) Open Sensor (B28) Open
590067). (Group 9015A-20.)
Wire M07 (PUR) Harness (W10) Transmission Harness (W10) - M07

Open (PUR) Open (Check/Repair)
Wire M07 (PUR) Harness (W3) Load Center Harness (W3) - M07
9015A
20 Open (PUR) Open (Check/Repair)
24
9015A-20.)

590067). (Group 9015A-15.)
Circuit Short-To-Ground Sensor (B28) Short-To-Ground Sensor (B28) Short-To-Ground
590067). (Group 9015A-20.)

(Check/Repair)
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)

092005
PN=248
References
Circuit Short-to-Power Sensor (B28) Short-To-Power Sensor (B28) Short-To-Power
590067). (Group 9015A-20.)

(Check/Repair)
(Check/Repair)
9015A
TCU (A3) TCU (Replace). See Check 20
Controller (S.N. —590067). (Group 25
9015A-20.)

590067). (Group 9015A-15.)
F0353 Transmission FWD High Transmission Control Solenoid (Y1) Transmission Control Solenoid (Y1)
Range Clutch Pack Solenoid Open Open (Check/Replace). See
Open Transmission Control Valve Repair.
(Repair Manual Group 0360)
(Blue) Open (Check/Repair)
Wire T04 (Blue) Harness (W10) Transmission Harness (W10) - T04

Open (Blue) Open (Check/Repair)
Wire T04 (Blue) Control Valve Transmission Control Valve Internal

Internal Harness Open Harness - T04 (Blue) Open
(Check/Repair). See Transmission
Manual Group 0360)

9015A-20.)

590067). (Group 9015A-15.)

092005
PN=249
References
Range Clutch Pack Solenoid Short-To-Ground Short-To-Ground (Check/Replace).
Short-To-Ground See Transmission Control Valve
Repair. (Repair Manual Group 0360)
Wire T04 (Blue) Harness (W3) Load Center Harness (W3) - T04
Short-To-Ground (Blue) Short-To-Ground
(Check/Repair)

(Check/Repair)

9015A
20 Internal Harness Short-To-Ground Harness - T04 (Blue)
26 Short-To-Ground (Check/Repair).
See Transmission Control Valve

9015A-20.)

590067). (Group 9015A-15.)
Range Clutch Pack Solenoid Short-To-Power Short-To-Power (Check/Replace).
Short-To-Power See Transmission Control Valve
to Power (Blue) Short-To-Power
(Check/Repair)

Short-To-Power (Blue) Short-To-Power
(Check/Repair)

Internal Harness Short-To-Power Harness - T04 (Blue)
Short-To-Power (Check/Repair). See
Transmission Control Valve Repair.

092005
PN=250
References

9015A-20.)

590067). (Group 9015A-15.)
F0356 Transmission Third Speed Transmission Control Solenoid (Y4) Transmission Control Solenoid (Y4)
Clutch Pack Solenoid Open Open Open (Check/Replace). See
9015A
(Blue) Open (Check/Repair) 20
27

(Check/Repair. See Transmission
Manual Group 0360)

9015A-20.)

590067). (Group 9015A-15.)
F0357 Transmission Third Speed Transmission Control Solenoid (Y4) Transmission Control Solenoid (Y4)
Clutch Pack Solenoid Short-To-Ground Short-To-Ground (Check/Replace).
Short-to-Ground See Transmission Control Valve
(Check/Repair)

(Check/Repair)

092005
PN=251
References

Internal Harness Short-To-Ground Harness - T06 (Blue)
Short-To-Ground (Check/Repair).

9015A-20.)

590067). (Group 9015A-15.)
9015A
20 F0358 Transmission Third Speed Transmission Control Solenoid (Y4) Transmission Control Solenoid (Y4)
28 Clutch Pack Solenoid Short-To- Short-To-Power Short-To-Power (Check/Replace).
Power See Transmission Control Valve
(Check/Repair)

(Check/Repair)

Manual Group 0360)

9015A-20.)

590067). (Group 9015A-15.)
F0359 Transmission Second Transmission Control Solenoid (Y6) Transmission Control Solenoid (Y6)
Speed Clutch Pack Solenoid Open Open (Check/Replace). See

092005
PN=252
References


Manual Group 0360)

9015A
9015A-20.) 20
29
590067). (Group 9015A-15.)
Speed Clutch Pack Solenoid Short-To-Ground Short-To-Ground (Check/Replace).
(Check/Repair)

(Check/Repair)


9015A-20.)

590067). (Group 9015A-15.)

092005
PN=253
References
Speed Clutch Pack Solenoid Short-To-Power Short-To-Power (Check/Replace).
(Check/Repair)

(Check/Repair)

9015A
20 Internal Harness Short-To-Power Harness - T08 (Blue)
30 Short-To-Power (Check/Repair). See

9015A-20.)

590067). (Group 9015A-15.)
F0362 Transmission First Speed Transmission Control Solenoid (Y3) Transmission Control Solenoid (Y3)


Manual Group 0360)

092005
PN=254
References

9015A-20.)

590067). (Group 9015A-15.)
F0363 Transmission First Speed Transmission Control Solenoid (Y3) Transmission Control Solenoid (Y3)
Clutch Pack Solenoid Short-To-Ground Short-To-Ground (Check/Replace).
9015A
Short-To-Ground (Blue) Short-To-Ground 20
(Check/Repair) 31

(Check/Repair)


9015A-20.)

590067). (Group 9015A-15.)
F0364 Transmission First Transmission Control Solenoid (Y3) Transmission Control Solenoid (Y3)
Solenoid Speed Clutch Pack Short-To-Power Short-To-Power (Check/Replace).
(Check/Repair)

092005
PN=255
References

(Check/Repair)


9015A-20.)
9015A
20 MDU (Reconfigure). See Monitor
32 Display Unit—Service Menu (S.N. —
590067). (Group 9015A-15.)
F0365 Transmission Reverse Transmission Control Solenoid (Y2) Transmission Control Solenoid (Y2)
Wire T03 (Blue) Control Valve Transmission Harness (W10) - T03

Harness Open (Blue) Open (Check/Repair)

Manual Group 0360)

9015A-20.)

590067). (Group 9015A-15.)

092005
PN=256
References
Clutch Pack Solenoid Short-To- Short-To-Ground Short-To-Ground (Check/Replace).
Ground See Transmission Control Valve
(Check/Repair)

(Check/Repair)

9015A
Internal Harness Short-To-Ground Harness - T03 (Blue) 20
Short-To-Ground (Check/Repair). 33

9015A-20.)

590067). (Group 9015A-15.)
Clutch Pack Solenoid Short-To-Power Short-To-Power (Check/Replace).
(Check/Repair)

(Check/Repair)


092005
PN=257
References

9015A-20.)

590067). (Group 9015A-15.)
F0368 Transmission FWD Low Transmission Control Solenoid (Y5) Transmission Control Solenoid (Y5)
Range Clutch Pack Solenoid Open Open (Check/Replace). See
9015A
20 (Blue) Open (Check/Repair)
34

Manual Group 0360)

9015A-20.)

590067). (Group 9015A-15.)
F0369 Transmission FWD Low Transmission Control Solenoid (Y5) Transmission Control Solenoid (Y5)
Range Clutch Pack Solenoid Short-To-Ground Short-To-Ground (Check/Replace).
(Check/Repair)

(Check/Repair)

092005
PN=258
References


9015A-20.)

590067). (Group 9015A-15.)
9015A
F0370 Transmission FWD Clutch Transmission Control Solenoid (Y5) Transmission Control Solenoid (Y5) 20
Pack Solenoid Short-To-Power Short-To-Power Short-To-Power (Check/Replace). 35
(Check/Repair)

(Check/Repair)


9015A-20.)

590067). (Group 9015A-15.)
F0375 Transmission Gear Shifter Switch (Gear Selector) (S10) Shifter Switch (S10) (Gear Selector)
Selector Open Open (Check/Repair)
Wire P24 (Red) Harness (W4) Open Front Console Harness (W4) P24
(Red) Open (Check/Repair)

092005
PN=259
References
Wire P24 (Red) Harness (W3) Open Load Center Harness (W3) P24

9015A-20.)
F0377 Transmission Oil Transmission Oil Temperature Transmission Oil Temperature

Temperature Circuit Sensor (B32) Short-To-Power Sensor (B32) Short-To-Power
Short-To-Power (Check/Replace). See Electrical
590067). (Group 9015A-20.)
Wire X06 (Yellow) Harness (W3) Load Center Harness (W3) - X06
9015A
20 Short-To-Power (Yellow) Short-To-Power
36 (Check/Repair)
Wire X06 (Yellow) Harness (W10) Transmission Harness (W10) - X06

(Check/Repair)
F0378 Transmission Oil Transmission Oil Temperature Transmission Oil Temperature

Temperature Circuit Open Sensor (B32) Open Sensor (B32) Open
590067). (Group 9015A-20.)
Open (Yellow) Open (Check/Repair)


9015A-20.)

590067). (Group 9015A-15.)
F0379 Transmission FNR Shifter Switch (FNR) (S10) Open Shifter Switch (S10) Replace
Selector Switch Open
Wire P23 (Red) Harness (W4) Open Front Console Harness (W4) - P23

092005
PN=260
References
Wire T13 (Blue) Harness (W4) Open Front Console Harness (W4) - T13
Wire T14 (Blue) Harness (W4) Open Front Console Harness (W4) - T14
Wire E02 (White) Harness (W4) Front Console Harness (W4) - E02
Open (White) Open (Check/Repair)

9015A-20.)

9015A
Display Unit—Service Menu (S.N. — 20
590067). (Group 9015A-15.) 37
F0380 Transmission Oil Filter Transmission Oil Filter Restriction Transmission Oil Filter Restriction
Restricted Switch (B20) Short-To-Ground Switch (B20) Short-To-Ground
(Check/Replace)
Wire N03 (Yellow) Harness (W10) Transmission Harness (W10) — N03

Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F0384 Reverse Alarm Relay Back-Up Alarm Relay (K10) Back-Up Alarm Relay (K10)
Short-To- Power Short-To-Power Short-To-Power (Check/Replace)
(Check/Repair)

092005
PN=261
References

9015A-20.)

590067). (Group 9015A-15.)
F0385 Reverse Alarm Relay Back-Up Alarm Relay (K10) Back-Up Alarm Relay (K10)
Short-to-Ground Short-To-Ground Short-To-Ground (Check/Replace)
(Check/Repair)
9015A
20
9015A-20.)

590067). (Group 9015A-15.)
F0386 Reverse Alarm Relay Open Back-Up Alarm Relay (K10) Open Back-Up Alarm Relay (K10) Open
(Check/Replace)
Back-Up Alarm Relay Fuse (F13) Park Brake And Back-Up Alarm
Open Fuse (F13) Open (Check/Replace)

9015A-20.)

590067). (Group 9015A-15.)
F0387 Park Brake Solenoid Transmission Park Brake Release Transmission Park Brake Release
Short-to- Power Solenoid (Y19) Short-To-Power Solenoid (Y19) Short-To-Power
(Check/Replace)

092005
PN=262
References
Wire T09 (Blue) Harness (W2) Loader Frame Harness (W2) - T09
(Check/Repair)
(Check/Repair)

9015A-20.)

9015A
590067). (Group 9015A-15.) 20
39
F0388 Park Brake Solenoid Transmission Park Brake Release Transmission Park Brake Release
Short-to- Ground Solenoid (Y19) Short-To-Ground Solenoid (Y19) Short-To-Ground
(Check/Replace)
Wire T09 (Blue) Harness (W2) Loader Frame Harness (W2) - T09
(Check/Repair)
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F0389 Park Brake Solenoid Open Engine Controller Switched 15 A Engine Controller Switched 15 A
Fuse Bad Fuse Check/Replace
Transmission Park Brake Release Transmission Park Brake Release

Solenoid (Y19) Open Solenoid (Y19) Open
(Check/Replace)
Wire T09 (Blue) Harness (W2) Open Loader Frame Harness (W2) - T09

092005
PN=263
References

9015A-20.)

590067). (Group 9015A-15.)
F0396 Transmission Oil Transmission Oil Type Wrong Transmission Oil Type
Temperature High (Check/Replace). See Transmission,
9015A
20 Differential Oil. (Operator’s Manual.)
40
Transmission Oil Level See Check Transmission Oil Level.
(Operator’s Manual)
Transmission Oil Cooler Internal Transmission Oil Cooler Internal

Restriction Restriction (Check/Repair)
Transmission Oil Cooler Air Flow Transmission Oil Cooler Air Flow
Restriction Restriction (Check/Repair). See
Transmission Oil Cooler, Hydraulic
Oil Cooler, Air-to-Air Aftercooler, and
Radiator External Cleaning
Procedure. (Operator’s Manual)
Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen
Plugged Plugged (Check/Replace)

Manual Group 0360)
Converter Relief Valve Stuck Open Torque Converter Relief Valve

(Check/Repair)
Transmission Main Pressure Transmission Main Pressure

Regulating Valve Spring Broken Regulating Valve Spring Broken
(Check/Replace)

092005
PN=264
References
Transmission Oil Cooler Relief Transmission Oil Cooler Relief

Bypass Valve Stuck Open Bypass Valve Stuck Open
(Check/Repair)

(Check/Replace)
Transmission Oil Temperature Transmission Oil Temperature

Sensor (B32) Short-To-Ground Sensor (B32) Short-To-Ground
590067). (Group 9015A-20.)
9015A
Short-To-Ground (Yellow) Short-To-Ground 20
(Check/Repair) 41

(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
TX,9015,111902 –19–04SEP03–37/37

092005
PN=265
References
Engine Related Diagnostic Trouble Codes

(S.N. —590067)
These DTCs are related to engine operation, but not

created by the Engine Control Unit (ECU).
F0400 Engine Oil Pressure Low Engine Oil Pressure Switch (B24) Engine Oil Pressure Switch (B24)
Long Short-To-Ground Short-To-Ground (Check/Replace).
Tell-Tale Code displayed in MDU

9015A Diagnostic Trouble Codes (S 02).
20 (Group 9015A-15.)
42
Engine Oil Pressure Sensor (B23) Engine Oil Pressure Sensor (B23)
Short-To-Ground (Check/Replace).
(Group 9015A-20.)
Wire N02 (Yellow) Harness (W6) Engine Harness (W6) - N02 (Yellow)
Short-To-Ground Short-To-Ground (Check/Repair)
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F0415 CCU Throttle Circuit (CCU) (CCU) Analog Throttle Position

Voltage Low Sensor (B14) Short To Ground
Analog Throttle Position Sensor (Check/Replace)
(B14) Shorted to Ground
Wire E12 (Yellow) Harness (W3) Load Center Harness (W3) - E12
Short to Ground (White) Short To Ground
(Check/Repair)

092005
PN=266
References

9015A-20.)
F0416 CCU Throttle Circuit (CCU) Analog Throttle Position (CCU) Analog Throttle Position
Voltage High Sensor (B14) Shorted to Battery Sensor (B14) Short To Battery
(Check/Replace)
Wire E12 (White) Harness (W3) Load Center Harness (W3) - E12
Short to Battery (White) Short To Battery
(Check/Repair)
ECU (A1) ECU (Replace)

9015A
ECU (Reprogram) 20
43
F0478 Engine Oil Pressure Engine Oil Pressure Sensor (B23) Engine Oil Pressure Sensor (B23)
Circuit Voltage Low Short-To-Ground (Check/Replace).
(Group 9015A-20.)
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F0479 Engine Oil Pressure Engine Oil Pressure Sensor (B23) Engine Oil Pressure Sensor (B23)
Circuit Voltage High Short-To-Power Short-To-Power (Check/Replace).
(Group 9015A-20.)
Short-To-Power Short-To-Power

092005
PN=267
References
CCU (A2) CCU (A2) (Replace). See Check

9015A-20.)

590067). (Group 9015A-15.)
F0499 Engine Oil Pressure Low Engine Oil Level Too High or Too Engine Oil Level (Check). See
Low Check Engine Oil Level. (Operator’s
Manual.)
9015A
20
44 Wrong Oil Type Engine Oil (Drain/Refill). See Diesel
Engine Oil. See Change Engine Oil
and Replace Filter. (Operator’s
Manual)
Engine Oil Filter Engine Oil Filter Restricted

(Check/Replace). See Change
Engine Oil and Replace Filter.
(Operator’s Manual)
Oil Passages Restricted Engine Oil Passage (Check/Clean)
Engine Oil Pump Engine Oil Pump (Check/Replace)
Engine Oil Pressure Sensor (B23) Engine Oil Pressure Sensor (B23)
Open Open (Check/Replace). See
(S.N. —590067). (Group 9015A-20.)
Open Open (Check/Repair)
Open (Yellow) Open
CCU (A2) CCU (A2) (Replace). See Check

9015A-20.)

092005
PN=268
References

590067). (Group 9015A-15.)
F0500 Engine Coolant Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor
Temperature High Long (CCU) (B1) Open (CCU) (B1) Open (Check/Replace).
Tell-Tale Code displayed in MDU Specifications (S.N. —590067).
“Service” menu. See Monitor (Group 9015A-20.)
(Group 9015A-15.)
9015A
Wire X04 (Yellow) Harness (W3) Load Center Harness (W3) - X04 20
Open (Yellow) Open (Check/Repair) 45
Wire X04 (Yellow) Harness (W6) Engine Harness (W6) - X04 (Yellow)

9015A-20.)

590067). (Group 9015A-15.)
F0515 Engine Air Filter Engine Air Filter Restriction Switch Engine Air Filter Restriction Switch
Restriction Circuit (B19) Short-To-Ground (B19) Short-To-Ground
(Check/Repair)
Wire M06 (Purple) Harness (W6) Engine Harness (W6) - M06 (Purple)
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)

092005
PN=269
References
F0516 Fuel Level Circuit Voltage Fuel Level Sender (B17) Fuel Level Sender (B17)
Low Short-To-Ground Short-To-Ground (Check/Replace)
Wire Y02 (Yellow) Harness (W5) Engine Frame Harness (W5) - Y02
(Check/Repair)
Wire Y02 (Yellow) Harness (W3) Load Center Harness (W3) - Y02
(Check/Repair)

9015A-20.)
9015A
20
590067). (Group 9015A-15.)
F0517 Engine Fuel Level Circuit Fuel Level Sender (B17) Open Fuel Level Sender (B17) Open
Open (Check/Replace)
Wire Y02 (Yellow) Harness (W5) Engine Frame Harness (W5) - Y02
Wire Y02 (Yellow) Harness (W3) Load Center Harness (W3) - Y02

9015A-20.)

590067). (Group 9015A-15.)
Temperature Circuit Noisy (CCU) (B1) Noisy (CCU) (B1) Noisy (Check/Replace).
(Group 9015A-20.)
Noisy (Yellow) Noisy (Check/Repair)

092005
PN=270
References
Noisy Noisy (Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
Temperature Circuit Short-To- (CCU) (B1) Short-To-Ground (CCU) (B1) Short-To-Ground
Ground (Check/Replace). See Electrical
9015A
Component Specifications (S.N. — 20
590067). (Group 9015A-20.) 47
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
Temperature Circuit Open (CCU) (B1) Open (CCU) (B1) Open (Check/Replace).
(Group 9015A-20.)

9015A-20.)

092005
PN=271
References

590067). (Group 9015A-15.)
F0580 Engine Air Filter Engine Air Filter Restriction Switch Engine Air Filter Restriction Switch
Restricted (B19) Short-To-Power (B19) Short-To-Power
(Check/Repair)
Wire M06 (Purple) Harness (W6) Engine Harness (W6) - M06 (Purple)
Short-To-Power Short-To-Power (Check/Repair)
(Check/Repair)
9015A
20
48 CCU (A2) CCU (Replace). See Check
9015A-20.)

590067). (Group 9015A-15.)
F0599 Engine Coolant Radiator Coolant Level Too Low Radiator Coolant Level Too Low
Temperature High (Check/Adjust). See Check Radiator
Coolant Level. (Operator’s Manual.)
Radiator Cap Leaking Radiator Cap Leaking

(Check/Replace)
Engine Fan Belt Worn or Loose Engine Fan Belt Worn or Loose
(Check/Adjust). See Serpentine Belt
Remove And Install. (Repair Manual,
Group 0510.)
Engine Fan on Backwards Engine Fan on Backwards

(Check/Adjust). See Fan And Fan
Drive Remove And Install. (Repair
Manual, 0510.)
Noisy Noisy (Check/Repair)

092005
PN=272
References
Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor

(B1) Resistance Out of Specification (CCU) (B1) Resistance Out of
Specification (Check/Replace). See
(S.N. —590067). (Group 9015A-20.)
Wire G01 (Black) Harness (W3) Load Center Harness (W3) - G01
Poor Connection (Black) Poor Connection
(Check/Repair)

9015A
Controller (S.N. —590067). (Group 20
9015A-20.) 49

590067). (Group 9015A-15.)
TX17961,0000006 –19–12AUG02–8/8

092005
PN=273
References
Engine Diagnostic Trouble Codes (S.N. —

590067)
NOTE: Some engine codes are listed more than once.

Access codes with Service ADVISOR to
determine SPN.FMI number. If using monitor both
diagnostic procedures should be followed.
Diagnostic Trouble Codes without an “F” prefix

are not displayed on the monitor. These DTCs
use the SPN.FMI format (000000.00) and are only
accessible with Service ADVISOR.
Wire harness information (Group 9015A-10):
9015A • See System Functional Schematic (S.N. —590067)

20 • See Loader Frame Harness (W2) Component Location
50 (S.N. —590067)
• See Load Center Harness (W3) Component Location
(S.N. —590067)
• See Front Console Harness (W4) Component Location
(S.N. —590067)
• See Engine Frame Harness (W5) Component Location
(S.N. —590067)
• See Engine Harness (W6) Component Location
Diagram (S.N. —590067)
• See Engine Air Heater Harness (W7) Component
Location (S.N. —590067)
F0423 (000105.03) Manifold Air Temperature Input See LEVEL 9 ECU - DTC SPN 105
Voltage High FMI 3 MANIFOLD AIR
TEMPERATURE INPUT VOLTAGE
HIGH DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM255.
F0424 (000105.04) Manifold Air Temperature Input See LEVEL 9 ECU - DTC SPN 105
Voltage Low FMI 4 MANIFOLD AIR
LOW DIAGNOSTIC PROCEDURE in
Continued on next page RG40854,0000003 –19–08AUG02–1/10

092005
PN=274
References
F0425 (000110.03) Engine Coolant Temperature Input See LEVEL 9 ECU - DTC SPN 110
Voltage High FMI 3 ENGINE COOLANT
CTM255.
F0426 (000110.04) Engine Coolant Temperature Input See LEVEL 9 ECU - DTC SPN 110
Voltage Low FMI 4 ENGINE COOLANT
F0431 (000651.05) Cylinder #1 EI Circuit Open See LEVEL 9 ECU - DTC SPN 651
9015A
FMI 5 CYLINDER #1 EI CIRCUIT 20
OPEN DIAGNOSTIC PROCEDURE 51
CTM255.
F0431 (000651.06) Cylinder #1 EI Circuit Shorted See LEVEL 9 ECU - DTC SPN 651
FMI 6 CYLINDER #1 EI CIRCUIT
SHORTED DIAGNOSTIC
160 of CTM255.
OPEN DIAGNOSTIC PROCEDURE
CTM255.
SHORTED DIAGNOSTIC
160 of CTM255.
CTM255.

092005
PN=275
References
SHORTED DIAGNOSTIC
160 of CTM255.
CTM255.
9015A
20 SHORTED DIAGNOSTIC
52 PROCEDURE in Section 04, Group
160 of CTM255.
CTM255.
SHORTED DIAGNOSTIC
160 of CTM255.
CTM255.
SHORTED DIAGNOSTIC
160 of CTM255.

092005
PN=276
References
F0437 (000174.03) Fuel Temperature Input Voltage High See LEVEL 9 ECU - DTC SPN 174
FMI 3 FUEL TEMPERATURE
INPUT VOLTAGE HIGH
F0438 (000174.04) Fuel Temperature Input Voltage Low See LEVEL 9 ECU - DTC SPN 174
FMI 4 FUEL TEMPERATURE
INPUT VOLTAGE LOW
F0439 (001347.05) Pump Control Valve #1 Error See LEVEL 9 ECU - DTC SPN 1347
FMI 5 PUMP CONTROL VALVE #1
9015A
ERROR DIAGNOSTIC 20
PROCEDURE in Section 04, Group 53
160 of CTM255.
F0440 (001348.05) Pump Control Valve #2 Error See LEVEL 9 ECU - DTC SPN 1348
FMI 05 PUMP CONTROL VALVE #2
ERROR DIAGNOSTIC
160 of CTM255.
F0441 (000637.08) Crank Position Input Missing See LEVEL 9 ECU - DTC SPN 637
FMI 08 CRANK POSITION INPUT
MISSING DIAGNOSTIC
160 of CTM255.
F0442 (000637.02) Crank Position Input Noise See LEVEL 9 ECU - DTC SPN 636
NOISE DIAGNOSTIC PROCEDURE
CTM255.
F0442 (000637.10) Crank Position Input Pattern Error See LEVEL 9 ECU - DTC SPN 637
PATTERN ERROR DIAGNOSTIC
160 of CTM255.

092005
PN=277
References
F0443 (000636.08) Pump Position Sensor Input Missing See LEVEL 9 ECU - DTC SPN 636
FMI 08 PUMP POSITION SENSOR
INPUT MISSING DIAGNOSTIC
160 of CTM255.
F0444 (000636.02) Pump Position Sensor Input Noise See LEVEL 9 ECU - DTC SPN 636
FMI 02 PUMP POSITION SENSOR
INPUT NOISE DIAGNOSTIC
160 of CTM255.
F0444 (000636.10) Pump Position Sensor Input Pattern See LEVEL 9 ECU - DTC SPN 636
Error FMI 10 PUMP POSITION SENSOR
9015A
20 INPUT PATTERN ERROR
54 DIAGNOSTIC PROCEDURE in
F0445 (000637.07) Crank Position/Pump Position Timing See LEVEL 9 ECU - DTC SPN 637
Moderately Out of Sync FMI 7 CRANK POSITION/PUMP
POSITION TIMING MODERATELY
OUT OF SYNC DIAGNOSTIC
160 of CTM255.
F0450 (000094.03) Fuel Rail Pressure Input Voltage See LEVEL 9 ECU - DTC SPN 94
High FMI 3 FUEL RAIL PRESSURE
INPUT VOLTAGE HIGH
DIAGNOSTIC PROCEDUREin
F0451 (000094.04) Fuel Rail Pressure Input Voltage See LEVEL 9 ECU - DTC SPN 94
Low FMI 3 FUEL RAIL PRESSURE
INPUT VOLTAGE LOW
F0453 (000097.03) Water in Fuel Signal Voltage High See LEVEL 9 ECU - DTC SPN 97
FMI 3 WATER IN FUEL SIGNAL
VOLTAGE HIGH DIAGNOSTIC
160 of CTM255.

092005
PN=278
References
F0454 (000097.04) Water in Fuel Signal Voltage Low See LEVEL 9 ECU - DTC SPN 97
FMI 4 WATER IN FUEL SIGNAL
VOLTAGE LOW DIAGNOSTIC
160 of CTM255.
F0455 (000105.16) Manifold Air Temperature Moderately See LEVEL 9 ECU - DTC SPN 105
High FMI 16 MANIFOLD AIR
TEMPERATURE MODERATELY
CTM255.
F0456 (001348.10) Pump Control Valve #2 Fuel Flow See LEVEL 9 ECU - DTC SPN 1348
9015A
Not Detected FMI 10 PUMP CONTROL VALVE #2 20
FUEL FLOW NOT DETECTED 55
F0469 (001347.10) Pump Control Valve #1 Fuel Flow See LEVEL 9 ECU - DTC SPN 1347
Not Detected FMI 10 PUMP CONTROL VALVE #1
FUEL FLOW NOT DETECTED
F0470 (001347.07) Fuel Rail Pressure Control Error See LEVEL 9 ECU - DTC SPN 1347
FMI 7 FUEL RAIL PRESSURE
CONTROL ERROR DIAGNOSTIC
160 of CTM255.
F0471 (001080.04) Fuel Rail Pressure Sensor Supply See LEVEL 9 ECU - DTC SPN 1080
Voltage Low FMI 4 FUEL RAIL PRESSURE
SENSOR SUPPLY VOLTAGE LOW
F0485 (000097.16) Water in Fuel Detected See LEVEL 9 ECU - DTC SPN 97
FMI 16 WATER IN FUEL
DETECTED DIAGNOSTIC
160 of CTM255.

092005
PN=279
References
000091.09 CAN Throttle Invalid See LEVEL 9 ECU - T7 - CAN

THROTTLE INVALID DIAGNOSTIC
160 of CTM255.
000094.10 Fuel Rail Pressure Loss Detected See LEVEL 9 ECU - DTC SPN 94
LOSS DETECTED DIAGNOSTIC
160 of CTM255.
000094.13 Fuel Rail Pressure Higher Than See LEVEL 9 ECU - DTC SPN 94
Expected FMI 13 FUEL RAIL PRESSURE
HIGHER THAN EXPECTED
9015A
20 DIAGNOSTIC PROCEDURE in
56 Section 04, Group 160 of CTM255.
000094.17 Fuel Rail Pressure Not Developed See LEVEL 9 ECU - DTC SPN 94
NOT DEVELOPED DIAGNOSTIC
160 of CTM255.
000110.00 Engine Coolant Temperature High See LEVEL 9 ECU - DTC SPN 110
Extremely High FMI 0 ENGINE COOLANT
TEMPERATURE HIGH MOST
SEVERE DIAGNOSTIC
160 of CTM255.
000110.16 Engine Coolant Temperature See LEVEL 9 ECU - DTC SPN 110
Moderately High FMI 16 ENGINE COOLANT
TEMPERATURE HIGH
MODERATELY SEVERE
000158.17 ECU Power Down Error See LEVEL 9 ECU - DTC SPN 158
FMI 17 ECU POWER DOWN
ERROR DIAGNOSTIC
160 of CTM255.

092005
PN=280
References
000174.16 Fuel Temperature High Moderately See LEVEL 9 ECU - DTC SPN 174
Severe FMI 16 FUEL TEMPERATURE
HIGH MODERATELY SEVERE
000611.03 Electronic Injector Wiring Shorted To See LEVEL 9 ECU - DTC SPN 611
Power Source FMI 3 ELECTRONIC INJECTOR
WIRING SHORTED TO POWER
SOURCE DIAGNOSTIC
160 of CTM255.
000611.04 Electronic Injector Wiring Shorted To See LEVEL 9 ECU - DTC SPN 611
9015A
Ground FMI 4 ELECTRONIC INJECTOR 20
WIRING SHORTED TO GROUND 57
000620.03 Sensor Supply 1 Voltage High See LEVEL 9 ECU - DTC SPN 620
FMI 3 SENSOR SUPPLY 1
160 of CTM255.
000620.04 Sensor Supply 1 Voltage Low See LEVEL 9 ECU - DTC SPN 620
FMI 4 SENSOR SUPPLY 1
160 of CTM255.
000627.01 Electronic Injector Supply Voltage See LEVEL 9 ECU - DTC SPN 627
Problem FMI 1 ELECTRONIC INJECTOR
SUPPLY VOLTAGE PROBLEM
000629.13 ECU Error See LEVEL 9 ECU - DTC SPN 629

FMI 13 ECU ERROR in Section 04,
Group 160 of CTM255.
000639.13 CAN Bus Error See LEVEL 9 ECU - DTC SPN 639
FMI 13 CAN BUS ERROR

092005
PN=281
References
000651.07 Cylinder #1 EI Fuel Delivery Failure See LEVEL 9 ECU - DTC SPN 651
FMI 7 CYLINDER #1 EI FUEL
DELIVERY FAILURE DIAGNOSTIC
160 of CTM255.
160 of CTM255.
9015A
20 DELIVERY FAILURE DIAGNOSTIC
58 PROCEDURE in Section 04, Group
160 of CTM255.
160 of CTM255.
160 of CTM255.
160 of CTM255.
001080.03 Fuel Rail Pressure Sensor Supply See LEVEL 9 ECU - DTC SPN 1080
Voltage High FMI 3 FUEL RAIL PRESSURE
SENSOR SUPPLY VOLTAGE HIGH

092005
PN=282
References
001568.02 Torque Curve Selection Invalid See LEVEL 9 ECU - DTC SPN 1568
FMI 2 TORQUE CURVE
SELECTION INVALID in Section 04,
001569.31 Fuel Derate See LEVEL 9 ECU - DTC SPN 1569

FMI 31 FUEL DERATE in Section
04, Group 160 of CTM255.
RG40854,0000003 –19–08AUG02–10/10
9015A
20
59

092005
PN=283
References
Steering and Brake Diagnostic Trouble

Codes (S.N. —590067)
F0998 Steering Pressure Circuit Steering System Pressure Switch Steering System Pressure Switch
(B25) Short-To-Ground (B25) Short-To-Ground
(Check/Repair)
Wire N08 (Yellow) Harness (W17) Secondary Steering Switch Harness

Short-To-Ground (W17) - N08 (Yellow)
Short-To-Ground (Check/Repair)
9015A (Check/Repair)
20
60 Monitor Configuration Wrong MDU (Reconfigure). See Monitor
590067). (Group 9015A-15.)
F0999 Steering Pressure Low Power for Pressure Switches Fuse Power for Pressure Switches Fuse
(F10) (F10) (Check/Replace)
Monitor Configuration Wrong MDU (Reconfigure). See Monitor

590067). (Group 9015A-15.)
Steering System Pressure Switch Steering System Pressure Switch

(B25) Open (B25) Open (Check/Repair)
Wire N08 (Yellow) Harness (W17) Secondary Steering Switch Harness

Short-To-Power (W17) - N08 (Yellow)
Short-To-Power (Check/Repair)
F1097 Service Brake Pressure Service Brake System Pressure Service Brake Pressure Switch (B27)
Circuit Switch (B27) Short-To-Power Short-To-Power (Check/Repair)
(Check/Repair)
F1099 Service Brake Pressure Service Brake System Pressure Service Brake Pressure Switch (B27)
Low Switch (B27) Open Open (Check/Repair)

092005
PN=284
References
Load Center Harness (W3) - T20 Load Center Harness (W3) - T20
(Blue) Open (Blue) Open (Check/Repair)
TX17961,0000003 –19–12AUG02–2/2
9015A
20
61

092005
PN=285
References
Electrical System Diagnostic Trouble Codes

(S.N. —590067)
F1620 Spare Relay 1 Driver Short CCU (A2) CCU (Replace). See Check
9015A-20.)

590067). (Group 9015A-15.)
9015A 9015A-20.)
20
590067). (Group 9015A-15.)
9015A-20.)

590067). (Group 9015A-15.)
9015A-20.)

590067). (Group 9015A-15.)
F1624 Air Preheat Driver Engine Air Heater Coil Relay (K34) Engine Air Heater Relay (K34)
Short-To- Ground Short-To-Ground Short-To-Ground (Check/Replace)
Wire E13 (White) Harness (W3) Load Center Harness (W3) - E13
Short-To-Ground (White) Short-To-Ground
(Check/Repair)

9015A-20.)

092005
PN=286
References

590067). (Group 9015A-15.)
F1625 Detent Enable Driver Monitor Configuration Wrong MDU (Reconfigure). See Monitor
Short-To-Ground Display Unit—Service Menu (S.N. —
590067). (Group 9015A-15.)
Detent Enable and Pilot Enable Detent Enable Relay (K32)

Relay (K32) Short-To-Ground Short-To-Ground (Check/Replace)
Wire H25 (Green) Harness (W3) Load Center Harness (W3) - H25
Short-To-Ground (Green) Short-To-Ground
(Check/Repair)
9015A
20
CCU (A2) CCU (Replace). See Check 63
9015A-20.)

590067). (Group 9015A-15.)
F1626 Ride Control Boom Driver Monitor Configuration Wrong MDU (Reconfigure). See Monitor
Short-To- Ground Display Unit—Service Menu. (Group
9015A-15.)
Ride Control Boom Relay (K30) Ride Control Boom Relay (K30)
Wire J04 (Tan) Harness (W3) Load Center Harness (W3) -J04
Short-To-Ground (Tan) Short-To-Ground
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F1628 Ride Control On Driver Monitor Configuration Wrong MDU (Reconfigure). See Monitor
Short-To- Ground Display Unit—Service Menu (S.N. —
590067). (Group 9015A-15.)

092005
PN=287
References
Ride Control (On/Off) Relay (K31) Ride Control (On/Off) Relay (K31)
Short-To-Ground Short-To-Ground (Check/Replace)
Wire J06 (Tan) Harness (W3) Load Center Harness (W3) - J06
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
9015A
20
64 F1629 Left Turn Driver Left Flasher Relay (K23) Left Flasher Relay (K23)
Short-To-Ground Short-To-Ground Short-To-Ground (Check/Replace)
Wire L08 (Brown) Harness (W3) Load Center Harness (W3) - L08
Short-To-Ground (Brown) Short-To-Ground
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F1630 Right Turn Driver Right Flasher Relay (K24) Right Flasher Relay (K24)
Short-To- Ground Short-To-Ground Short-To-Ground (Check/Replace)
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)

092005
PN=288
References
F1633 Secondary Steering Driver Monitor Configuration Wrong MDU (Reconfigure). See Monitor
590067). (Group 9015A-15.)
Secondary Steering Relay (K21) Secondary Steering Relay (K21)

Wire H14 (Green) Harness (W3) Load Center Harness (W3) - H14
Short-To-Ground (Green) Short-To-Ground
(Check/Repair)

9015A-20.)
9015A
20
MDU (Reconfigure). See Monitor 65
590067). (Group 9015A-15.)
F1634 Rear Wiper Driver Rear Intermittent Wiper Relay (K18) Rear Intermittent Wiper Driver Relay
Short-To-Ground Short-To-Ground (K18) Short-To-Ground
(Check/Replace)
Wire A29 (Orange) Harness (W3) Load Center Harness (W3) - A29
Short-To-Ground (Orange) Short-To-Ground
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F1635 Front Wiper Driver Front Intermittent Wiper Relay (K16) Front Intermittent Wiper Relay (K16)
Short-To-Ground Short-To-Ground Short-To-Ground (Check/Replace)
Wire A27 (Orange) Harness (W3) Load Center Harness (W3) - A27
Short-To-Ground (Orange) Short-To-Ground
(Check/Repair)

9015A-20.)

092005
PN=289
References

590067). (Group 9015A-15.)
F1636 CCU Relay Driver CCU (A2) CCU (Replace). See Check
Overtemp Controller (S.N. —590067). (Group
9015A-20.)

590067). (Group 9015A-15.)
F1637 CCU Timer Reset CCU (A2) CCU (Replace). See Check
9015A
20 9015A-20.)
66
590067). (Group 9015A-15.)
F1638 Proportional Fan Drive Y37 Variable Speed Fan Motor Check solenoid for short to ground,
Circuit Error Relief Solenoid circuit overload, or open circuit. See
System Functional Schematic
CCU output for proportional fan (S.N. —590067), section SE18. See
drive has short to ground, circuit Engine Frame Harness (W5)
overload, or open circuit Component Location (S.N. —
590067). Go to Group 9015A-10.
H35 Green Wire Check wire for short to ground,

circuit overload, or open circuit. See
(S.N. —590067), section SE18. See
Engine Frame Harness (W5)
Component Location (S.N. —
590067). Go to Group 9015A-10.
Normal operation: Supplies 0-12 V to

Y35.

092005
PN=290
References
R23 Black Wire Check wire for short to ground,

590067). Go to Group 9015A-10.
F1639 Reverse Fan Circuit Error Y38 Reverse Fan Solenoid Check solenoid for short to ground,
CCU output for reverse fan drive System Functional Schematic
has short to ground, circuit (S.N. —590067), section SE18. See
overload, or open circuit Engine Frame Harness (W5)
9015A
590067). Go to Group 9015A-10. 20
67
590067). Go to Group 9015A-10.
Normal operation: Supplies 24 V to

Y38.

590067). Go to Group 9015A-10.
F1641 Drive Light Switch Circuit Drive and Tail/Marker Light Switch Drive and Tail/Marker Switch (S26)
Open (S26) Open Open (Check/Replace)
Open (Brown) Open (Check/Repair)

9015A-20.)

092005
PN=291
References

590067). (Group 9015A-15.)
F1644 MDU Memory Bad MDU (H2) MDU (Replace)

590067). (Group 9015A-15.)
F1645 CCU Memory Bad CCU (A2) CCU (Replace). See Check
9015A-20.)
9015A
68 Display Unit—Service Menu (S.N. —
590067). (Group 9015A-15.)
F1647 Machine Odometer Bad MDU (H2) MDU (Replace)

(Group 9015A-15.)

590067). (Group 9015A-15.)
F1648 Machine Hourmeter Bad MDU (H2) MDU (Replace)

(Group 9015A-15.)

590067). (Group 9015A-15.)

092005
PN=292
References
F1649 CCU Hourmeter Bad CCU (A2) CCU (Replace). See Check
Tell-Tale Code displayed in MDU 9015A-20.)
(Group 9015A-15.)

590067). (Group 9015A-15.)
F1651 No ECU Transmit Wire M12 (Purple) Harness (W3) Load Center Harness (W3)—M12
9015A
Open (Purple) Open (Check/Repair.) 20
69
Wire M13 (Purple) Harness (W3) Load Center Harness (W3)—M13
Open (Purple) Open (Check/Repair.)
ECU ECU (Replace)

590067). (Group 9015A-15.)
F1653 No CCU Transmit Wire M12 (Purple) Harness (W3) Load Center Harness (W3)—M12
Wire M13 (Purple) Harness (W3) Load Center Harness (W3)—M13


9015A-20.)

590067). (Group 9015A-15.)
F1655 No TCU CAN Transmit Engine Controller Switched 15 A Engine Controller Switched 15 A
Fuse Bad Fuse Check/Replace
Wire M12 (Purple) Harness (W3) Load Center Harness (W3) M12

092005
PN=293
References
Wire M13 (Purple) Harness (W3) Load Center Harness (W3) M13
Wire R02 (Black) Harness (W3) Load Center Harness (W3) R02
Open (Black) Open (Check/Repair.)

9015A-20.)

590067). (Group 9015A-15.)
9015A
20 F1658 Battery Voltage Balance CCU 12 V Batt Unswitched Fuse CCU 12 V Batt Unswitched Fuse
70 (F9) Open (F9) Open (Check/Replace)
Wire P31 (Red) Harness (W3) Open Load Center Harness (W3) - P31
F1660 Alternator Voltage High Alternator (G4) Output Voltage Too Alternator (G4) Output Voltage Too
High High (Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F1661 Alternator Voltage Low Alternator Output Voltage Too Low Alternator (G4) Output Voltage Too
Low (Check/Repair)
Wire B10 (Red) Harness (W3) Open Load Center Harness (W3) - B10
CCU 28V Batt Switched Fuse (F11) CCU 28V Batt Unswitched Fuse
Open (F11) Open (Check/Replace)

9015A-20.)

092005
PN=294
References

590067). (Group 9015A-15.)
F1662 Power Voltage High Alternator (G4) Output Voltage Too Alternator G4 Output Voltage Too
High High (Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
9015A
20
F1663 Power Voltage Low CCU 28V Batt Switched Fuse (F11) CCU 28V Batt Switched Fuse (F11) 71
Open Open (Check/Replace)
Wire B10 (Red) Harness (W3) Open Load Center Harness (W3) - B10
F1664 Brake Light Pressure Brake Light Pressure Switch (B40) Brake Light Pressure Switch (B40)
Circuit Short-To-Ground Short-To-Ground (Check/Replace.)
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F1665 Drive Light Switch Circuit Drive and Tail/Marker Light Switch Drive and Tail/Marker Switch (S26)
(S26) Open Open (Check/Replace)
Open (Brown) Open (Check/Repair)

9015A-20.)

092005
PN=295
References

590067). (Group 9015A-15.)
F1667 Turn Switch Circuit Short Turn Switch (S25) Short-To-Ground Turn Switch (S25) Short-To-Ground
(Check/Repair)
Wire L07 (Brown) Harness (W4) Front Console Harness (W4) - L07
(Check/Repair)
Wire L10 (Brown) Harness (W4) Front Console Harness (W4) - L10
(Check/Repair)
9015A
20
72 MDU (H2) MDU (Replace)

590067). (Group 9015A-15.)
F1668 Hazard Switch Circuit 4-Way Flasher Switch (S24) 4-Way Flasher Switch (S24)
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F1671 Return-to-Carry Detent Return-to-Carry (RTC)/Float Detent Check solenoid for short to ground,
Solenoid Circuit Error Solenoid Coil in A4 Pilot Controller circuit overload, or open circuit. See
CCU output for Return-to-Carry (S.N. —590067), section SE27 and
Detent Solenoid has short to SE18. (Group 9015A-10.)
ground, circuit overload, or open
circuit

092005
PN=296
References

(S.N. —590067), section SE27 and
SE18. (Group 9015A-10.)

Return-to-Carry Detent Solenoid in
A4 Pilot Controller.

9015A
SE18. Go to Group 9015A-10. 20
73
F1672 Boom Height Kickout Boom Height Kickout Detent Check solenoid for short to ground,
Solenoid Circuit Error Solenoid Coil in A4 Pilot Controller circuit overload, or open circuit. See
CCU output for Boom Height (S.N. —590067), section SE27 and
Kickout Detent Solenoid has SE18. Go to Group 9015A-10.
short to ground, circuit overload,
or open circuit

SE18. Go to Group 9015A-10.

Boom Height Kickout Detent
Solenoid in A4 Pilot Controller.

SE18. Go to Group 9015A-10.
F1699 Configuration Error Controllers Not All Configured For MDU (Reconfigure). See Monitor
624H (Reconfigure) Display Unit—Service Menu (S.N. —
590067). (Group 9015A-15.)
TX17961,0000004 –19–12AUG02–12/12

092005
PN=297
References
Hydraulic System Diagnostic Trouble Codes

(S.N. —590067)
F2100 Hydraulic Oil Temperature Hydraulic Oil Temperature Sensor Hydraulic Oil Temperature Sensor
High Long (B15) Short-To-Ground (B15) Short-To-Ground
Tell-Tale Code displayed in MDU Component Specifications (S.N. —
“Service” menu. See Monitor 590067). (Group 9015A-20.)
(Group 9015A-15.)
9015A Wire X01 (Yellow) Harness (W5) Engine Frame Harness (W5) -X01
20 Short-To-Ground (Yellow) Short-To-Ground
74 (Check/Repair)
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F3115 Hydraulic Oil Filter Hydraulic Oil Filter Restriction Switch Hydraulic Oil Filter Restriction Switch
Restriction Short-To-Ground (B21) Short-To-Ground (B21) Short-To-Ground
(Check/Replace)
(Check/Repair)
Wire N01 (Yellow) Harness (W5) Engine Frame Harness (W5) - N01
(Check/Repair)

9015A-20.)

092005
PN=298
References

590067). (Group 9015A-15.)
F3150 Hydraulic Oil Filter Hydraulic Oil Filter Restriction Switch Hydraulic Oil Filter Restriction Switch
Restriction Circuit (B21) Short-To-Power (B21) Short-To-Power
Short-To-Power (Check/Replace)
(Check/Repair)
9015A
20
CCU (A2) CCU (Replace). See Check 75
9015A-20.)

590067). (Group 9015A-15.)
F3160 Ride Control Circuit Monitor Configuration Wrong MDU (Reconfigure). See Monitor
Short-to-Power Display Unit—Service Menu (S.N. —
590067). (Group 9015A-15.)
Ride Control Switch (S31) Ride Control Switch (S31)

Short-To-Power Short-To-Power (Check/Repair)
Short-To-Power (Tan) Short-To-Power
(Check/Repair)
Short-To-Power (Tan) Short-To-Power
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)

092005
PN=299
References
F3161 Ride Control Auto Circuit Monitor Configuration Wrong MDU (Reconfigure). See Monitor
590067). (Group 9015A-15.)

(Check/Repair)

9015A-20.)
9015A
20
590067). (Group 9015A-15.)
F3162 Ride Control On Circuit Monitor Configuration Wrong MDU (Reconfigure). See Monitor
590067). (Group 9015A-15.)

(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
F3163 Boom Position Sensor Boom Position Sensor (B9) Circuit Check sensor voltage using Service
Volts Low ADVISOR or monitor.
See Hydraulic Sensors (d 06) in See

Monitor Display Unit—Diagnostics
Menu (S.N. —590067). (Group
9015A-15.)

092005
PN=300
References
Boom Position Sensor (B9) Check sensor using multimeter

Specifications (S.N. —590067) for
specification. (Group 9015A-20.)
Short in Harness Check harnesses.
See Loader Frame Harness (W2)

590067). (Group 9015A-10.)
See Load Center Harness (W3)

9015A
590067). (Group 9015A-10.) 20
77
F3164 Boom Position Sensor Boom Position Sensor (B9) Circuit Check sensor voltage using Service
Volts High ADVISOR or monitor.
See Hydraulic Sensors (d 06) in See

Menu (S.N. —590067). (Group
9015A-15.)
Boom Position Sensor (B9) Check sensor using multimeter

Specifications (S.N. —590067) for
specification. (Group 9015A-20.)
Short in Harness Check harnesses.
See Loader Frame Harness (W2)

590067). (Group 9015A-10.)
See Load Center Harness (W3)

590067). (Group 9015A-10.)
F3171 Hydraulic Oil Pressure Hydraulic System Pressure Sensor Hydraulic System Pressure Sensor
Circuit Voltage Low (B8) (B8) Short To Battery
Short to Battery Component Specifications (S.N. —
590067). (Group 9015A-20.)

092005
PN=301
References
Short to Battery (Yellow) Short To Battery
(Check/Repair)
Short to Battery (Yellow) Short to Battery
(Check/Repair)

9015A-20.)
F3172 Hydraulic Oil Pressure Hydraulic System Pressure Sensor Hydraulic System Pressure Sensor
Circuit Voltage High (B8) Short to Ground (B8) Short To Ground
9015A
20 (Check/Replace). See Electrical
78 Component Specifications (S.N. —
590067). (Group 9015A-20.)
Short to Ground (Yellow) Short To Ground
(Check/Repair)
Short to Ground (Yellow) Short To Ground
(Check/Repair)

9015A-20.)
F3173 Spin Control Mode Circuit Spin Control Switch (Off/On) (S5) Spin Control Switch (Off/On) (S5)
Shorted to Battery Short To Battery (Check/Replace)
Wire H10 (Green) Harness (W14) Spin Control Mode Harness (W14)—
Short to Battery H10 (Green) Short To Battery
(Check/Repair)
Wire H10 (Green) Harness (W3) Load Center Harness (W3)—H10

Short to Battery (Green) Short to Battery

9015A-20.)
F3174 Spin Control Enable Spin Control Switch (Off/On) (S5) Spin Control Switch (Off/On) (S5)
Circuit Short-To-Ground Short-To-Ground Short-To- Ground (Check/Replace)

092005
PN=302
References
Wire H10 (Green) Harness (W14) Spin Control Mode Harness (W14)
Wire H10 (Green) Harness (W3) Load Center Harness (W3)


9015A-20.)
Circuit Short-To-Ground (B15) Short-To-Ground (B15) Short-To-Ground
9015A
590067). (Group 9015A-20.) 20
79
Wire X01 (Yellow) Harness (W5) Engine Frame Harness (W5) - X01
(Check/Repair)
(Check/Repair)

9015A-20.)

590067). (Group 9015A-15.)
Circuit Open (B15) Open (B15) Open (Check/Repair). See
(S.N. —590067). (Group 9015A-20.)

092005
PN=303
References
Circuit Noisy (B15) Noisy (B15) Noisy (Check/Replace). See
(S.N. —590067). (Group 9015A-20.)

9015A-20.)
9015A
20
590067). (Group 9015A-15.)
High (B15) Open (B15) Open (Check/Replace). See
(S.N. —590067). (Group 9015A-20.)
Wire X01 (Yellow) Harness (W5) Engine Frame Harness (W5)—X01


9015A-20.)

590067). (Group 9015A-15.)
TX17961,0000005 –19–12AUG02–7/7

092005
PN=304
References
Electrical Component Specifications (S.N. —

590067)
Listed below are specifications for different specifications

for machine sensors. If specification is not listed here, see
a recommended test procedure later in this group for the
component.
Access Loader Sensor Checkand Engine Sensor Check

template in SERVICE ADVISOR™ to check these
specifications.
See Monitor Display Unit—Diagnostics Menu (S.N. —

590067) to view sensor readings on monitor (Group
9015A-15.)
9015A
Item Measurement Specification 20
81
Engine Sensors
Fuel Temperature Sensor (B3) Temperature -40°C—110°C (-40°F—375°F)

Indicator light turns On at 107°C (225°F)
Engine Oil Temperature Sensor Temperature 50°—104°C (122°—219°F) normal

(B15) operation
Temperature -40° ± 125°C (-40° ± 257°F) full
operation
Voltage 1.0—3.2 volts normal operation
Temperature 104°C (219°F) STOP indicator turns
On
103°C (217°F) STOP indicator turns
Off
Voltage 4.732—4.762 volts at 0°C (32°F)
4.346—4.407 volts at 20°C (68°F)
1.285—1.344 volts at 100°C (212°F)
Resistance 178—183 ohms at 100°C (212°F)
6400 ohms at 0°C (32°F)
2190 ohms at 20°C (68°F)
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page TX17994,000032E –19–20JUN02–1/6

092005
PN=305
References
Item Measurement Specification
Engine Coolant Temperature Normal operating range 85°—107° C (185°—225° F)

Sensor (B1) Full operating range -40°—+125° C (-40°—+257° F)
Indicator light turns On at 107° C (225° F)
Indicator light turns Off at 106° C (223° F)
4.346—4.407 volts at 20°C (68°F)
1.285—1.344 volts at 100°C (212°F)
6400 ohms at 0°C (32°F)
2190 ohms at 20°C (68°F)
Fuel Level Sender (B17) Resistance Empty tank 10 Ohms

Resistance Half full tank 100 Ohms
Resistance Full Tank 180 Ohms
9015A
20
82 Engine Air Filter Restriction Switch Normally open. Closes on increasing 4.98—7.48 kPa G (20—30 in. of
(B19) pressure water)
Engine Oil Pressure Sensor (B23) Pressure 0—565 kPa (0—5.6 bar) (0—82 psi)
normal operation
Voltage 0.5—4.5 volts normal operation
Pressure 82.7 kPa (0.83 bar) (12 psi) ENGINE
OIL PRESSURE and STOP indicator
turns On
Pressure 89.6 kPa (0.89 bar) (13 psi) ENGINE
OIL PRESSURE and STOP indicator
turns Off
Transmission Sensors
Transmission Oil Filter Restriction Normally open; Closes at Pressure 345 ± 69 kPa (3.4 ± 0.7 bar) (50 ±
Switch (B20) 10 psi)
Indicator light turns On at 120°C (248°F)
Torque Converter Input Shaft Speed—Normal Operating Range 900—2350 rpm

Speed Sensor (Engine rpm) (B28)
Torque Converter Output Shaft Speed—Normal Operating Range 0—2350 rpm

Speed Sensor (B29)
Internal Clutch Speed Sensor Speed—Normal Operating Range 900—2350 rpm

(B30)
Continued on next page TX17994,000032E –19–20JUN02–2/6

092005
PN=306
References
Transmission Output Shaft Speed Speed—Normal Operating Range Varies according to ground speed
Sensor (B31)
Transmission Oil Temperature Temperature—Normal Operating 85°C—110°C (185°F—230°F)

Sensor (B32) Range
120°C (248°F) TRANS FAULT and
STOP indicator turns On
Temperature 119°C (246°F) TRANS FAULT and
STOP indicator turns Off
4.346—4.407 volts at 20°C (68°F)
1.285—1.344 volts at 100°C (212°F)
6400 ohms at 0°C (32°F)
9015A
2190 ohms at 20°C (68°F) 20
83
Clutch Cut-Off Sensor (B33) Voltage (Transmission goes to 1.2 Volts (Level ground setting)
neutral at:)
1.2 Volts (Small slope setting)
2.0 Volts (Steep slope setting)
Hydraulic Sensors
Hydraulic System Pressure Sensor Normal Operating Range 4826—24132 kPa (48.3—241.3 bar)
(B8) (700—3500 psi)
Normal Operating Voltage 0.5—4.5 volts
Hydraulic Oil Temperature Sensor Normal operating range 25°—104° C (77°—219° F)

(B15) Full operating range -40°—+125° C (-40°—+257° F)
Indicator light turns On at 104° C (219° F)
Indicator light turns Off at 103° C (217° F)
4.346—4.407 volts at 20°C (68°F)
1.285—1.344 volts at 100°C (212°F)
6400 ohms at 0°C (32°F)
2190 ohms at 20°C (68°F)
Hydraulic Oil Filter Restriction Normally Open; Closes when 345 ± 69 kPa (3.4 ± 0.7 bar) (50 ±
Switch (B21) differential pressure above Pressure 10 psi)

092005
PN=307
References
Steering System Pressure Switch Normally open; Closed during normal 240 kPa (2.4 bar) (35 psi)
(B25) operation and opens when steering
pressure drops below Pressure
Ride Control Pressure Switch Closing Pressure 414 kPa (4 bar) (60 psi)
(Normally Open) Opening Pressure 276 kPa (2.7 bar) (40 psi)
Brake Pressure Switches
Service Brake Pressure Switch Normally open; Closed during normal 2068 ± 193 kPa (21 ± 1.9 bar) (300
(B27) operation and opens when brake ± 28 psi)
9015A
20 pressure drops below Pressure
84
Park Brake Pressure Switch (B34) Normally Closed; Opens on 1241 ± 69 kPa (12 ± 0.7 bar) (180 ±
increasing pressure 10 psi)
Closes on decreasing pressure 1034 ± 103 kPa (10 ± 1 bar) (150 ±
15 psi)
Brake Pressure Switch (B40) Pressure 415 ± 275 kPa (6 ± 1.4 bar) (80 ± 20
(Normally Open) psi)
Secondary Steering
B25 Steering System Pressure Pressure 240 kPa (2.4 bar) (35 psi)
Switch (Secondary Steering)
(Normally Closed) Opens at Less
Than

092005
PN=308
References
9015A
20
85
–19–19SEP96
T102066

092005
PN=309
References
Monitor Gauge Ranges
Engine Oil Pressure Gauge Range (A) Red 16 kPa (0.14 bar) (2 psi)
Range (B) Red 82.7 kPa (0.83 bar) (12 psi)
Range (C) Green 100 kPa (1.03 bar) (15 psi)
Range (D) Green 500 kPa (5.03 bar) (73 psi)
Range (E) Green 704 kPa (7.03 bar) (102 psi)
Engine Coolant Temperature Gauge Range (A) Green Temp 38° C (100° F)
Range (B) Green Temp 60° C (140° F)
Range (C) Green Temp 99° C (210° F)
Range (D) Red Temp 107° C (225° F)
9015A
20 Range (E) Red Temp 121° C (250° F)
86
Hydraulic Oil Temperature Gauge Range (A) Green Temp 27° C (81° F)
Range (B) Green Temp 49° C (120° F)
Range (E) Red Temp 121° C (250° F)
Transmission Oil Temperature Range (A) Green Temp -20° C (-4° F)

Gauge Range (B) Green Temp 60° C (140° F)
Range (E) Red Temp 125° C (257° F)
Fuel Level Gauge Range (A) Red 0% Tank Empty

Range (B) Green 5% Tank Full
Range (C) Green 50% Tank Full
Range (D) Green 100% Tank Full
TX17994,000032E –19–20JUN02–6/6

092005
PN=310
References
Check Controller (S.N. —590067)
• Review diagnostic procedures closely before replacing

the controller.
• Verify connectors, wire crimps, 5 volt and 24 volt power
terminals, and ground terminals.
If a failed connection or wire is suspected to be the cause

of the intermittent problem: clear service codes, then
check the connection or wire by wiggling it while watching
for new service codes.
To check the connection between the harness and a

sensor or the harness and the controller, use JT07328,
Connector Adapter Test Kit.
9015A
Insert the male end of the appropriate test adapter into 20
the female end of the controller or sensor connector 87
terminal. There should be moderate resistance when the
test adapter is inserted into the terminal. If the connection
is loose, replace the female terminal.
If all other components related to the system failure have

checked OK, it is reasonable to assume the controller is
malfunctioning.
CED,TX17961,83 –19–27MAR00–1/2
Connector Adapter Test Kit . . . . . . . . . . . . . . JT07328
Used with JT07306 Digital Multimeter to make voltage and

resistance measurements in control system wiring harness
connectors. Can also be used to test terminals for proper
fit.
–UN–26NOV97
RG8803
CED,TX17961,83 –19–27MAR00–2/2

092005
PN=311
References
Check Battery Electrolyte Level And

Terminals (S.N. —590067)
1. Remove hold-down clamps.
2. Remove battery covers.
9015A
20
88

092005
PN=312
References
A—Battery Post
B—Fill Tube
C—Electrolyte Level Range
9015A
20
89
–UN–23AUG88
TS203
–UN–09SEP03
T6996DB
Single Level Fill Tube Application
–UN–09SEP03
T6996DA
Dual Level Fill Tube Application

092005
PN=313
References
CAUTION: Battery gas can explode. Keep

sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.
Always remove grounded (-) battery clamp first

and replace it last.
Sulfuric acid in battery electrolyte is poisonous.

It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
9015A
20 Avoid the hazard by:
90
1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10—15
minutes. Get medical attention immediately.
Specification
Flush Eyes With Water—Time ............................................ 10-15 minutes
If acid is swallowed:
1. Drink large amounts of water or milk.

2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
IMPORTANT: During freezing weather, batteries must

be charged after water is added to
prevent battery freezing. Charge battery
using a battery charger or by running
the engine.
3. Fill each cell to within specified range with distilled

water. DO NOT overfill.
TX,20,111118 –19–04SEP96–3/3

092005
PN=314
References
Procedure For Testing Batteries (S.N. —

590067)
Visual Check
1. Check for damage such as cracked or broken case

and electrolyte leakage.
If damage is seen, replace battery.
2. Check electrolyte level. (See procedure in this group)
If low, add distilled water to specified level and charge

battery.
3. Check terminals for corrosion. 9015A

20
If corroded, clean using a wire brush or battery post 91
cleaner such as JT05838 Battery Post/Clamp Cleaner.
4. Check posts for looseness.
If posts are loose, replace battery.
Hydrometer Test
1. Check specific gravity with a hydrometer or battery

tester such as JT05460 Coolant/Battery Tester.
2. Record specific gravity reading for each cell.
If high and low readings vary LESS than 0.050 and

average specific gravity is between 1.225 and 1.280,
battery is fully charged, go to LOAD TEST.

average specific gravity is LESS than 1.225, charge
battery and repeat test. If average specific gravity is
still LESS than 1.225, replace both batteries.
If high and low readings vary MORE than 0.050,

charge battery and repeat test. If high and low
readings still vary MORE than 0.050, replace both
batteries.

092005
PN=315
References
Load Test
1. Check battery capacity with a load tester such as

JT05832 Battery Load Tester. Follow tester
manufacturer’s instructions for proper load test
procedures.
2. If one battery fails load test, replace both batteries.
TX,20,111119 –19–01AUG96–2/2
9015A
20
92

092005
PN=316
References
Transmission Control Valve Solenoid Check (S.N. —590067)
9015A
20
93
–19–27AUG97
T110956
Continued on next page TX,15,111260 –19–13FEB97–1/2

092005
PN=317
References
Following is a simple test to check electrical operation terminal as shown.

of the transmission control valve solenoids:
Specification
1. Disconnect the X6 Transmission Harness to Load Control Valve Solenoid—
Resistance ...................................................................... 15—20 ohms
Center Harness Connector. (See Transmission
Harness (W10) Component Location in Group
3. This check can also be done at the X41
9015—10 for location on machine.)
Transmission Control Valve Connector.
2. Using an ohmmeter, check the resistance between
the common pin terminal (pin V) and each solenoid
TX,15,111260 –19–13FEB97–2/2
Clutch Cut-Off Sensor Check and Adjustment

9015A (S.N. —590067)
20
94 SPECIFICATIONS
Clutch Cut-Off Sensor Voltages
Pedal Up—Voltage 0.9 ± 0.1 volts
Pedal Fully Depressed—Voltage 4.5 ± 0.1 volts
Clutch Cut-Off Link—Starting 100—105 mm (3.9—4.1 in.)
Length
1. Turn key switch on.
2. SERVICE ADVISOR™ can be use to check sensor is

functioning properly. Connect to machine and Perform
Loader Sensor Check.
3. If not using Service ADVISOR, select (d 052) clutch

cut-off sensor voltage display on monitor. See Monitor
Display Unit—Diagnostics Menu to access.
4. Without stepping on either brake pedal, record clutch

cut-off voltage displayed on monitor.
Fully depress either brake pedal and record voltage

displayed on monitor. Both voltages should be within
specification.
Clutch Cut-Off Sensor Voltages—Specification

Pedal Up—Voltage .............................................................. 0.9 ± 0.1 volts
Pedal Fully Depressed—Voltage ........................................ 4.5 ± 0.1 volts
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page TX,20,111903 –19–14JUL00–1/3

092005
PN=318
References
5. If voltage is not within specification, disconnect end of

link with ball joint. Adjust link to specification. This
length is a starting point. Adjust as needed to meet the
voltage specifications.
Specification
Clutch Cut-Off Link—Starting
Length ............................................................ 100—105 mm (3.9—4.1 in.)
9015A
20
95
–UN–11AUG98
T116461B
Clutch Cut-Off Link Adjustment
TX,20,111903 –19–14JUL00–2/3
6. Reconnect link. Make sure brake pedal is in the up

position and verify voltage is within specification.
–19–12SEP97
T111379
d 052 Display
TX,20,111903 –19–14JUL00–3/3

092005
PN=319
References
Engine Control Unit Temperature Sensors

Test (S.N. —590067)
SPECIFICATIONS
Temperature Sensor Ranges
Manifold Air Temperature Sensor 3050 ± 30 ohms
(B7) Resistance
Coolant Temperature Sensor (B1) 2882 ± 30 ohms
Resistance
Fuel Temperature Sensor (B3) 2770 ohms
Resistance
1. Measure resistance as indicated. Resistance may vary

from one sensor to another.
9015A Temperature Sensor Ranges—Specification

20 Manifold Air Temperature Sensor
96 (B7)—Resistance.............................................................. 3050 ± 30 ohms
Coolant Temperature Sensor
(B1)—Resistance.............................................................. 2882 ± 30 ohms
Fuel Temperature Sensor (B3)—
Resistance ................................................................................ 2770 ohms
2. SERVICE ADVISOR™ can also be use to check

sensor is functioning properly with engine running.
Connect to machine and Perform Engine Sensor
Check.
For machine location of temperature sensors, See Engine

Harness (W6) Component Location Diagram (S.N. —
590067). (Group 9015A-10.)
SERVICE ADVISOR is a trademark of Deere & Company TX17994,0000345 –19–09SEP02–1/1

092005
PN=320
References
Engine Control Unit Speed Sensors Test

(S.N. —590067)
SPECIFICATIONS
Speed Sensor Ranges
Injection Pump Position Sensor 2000 ± 30 ohms
(B4) Resistance
Crank Position Sensor (B3) 3000 ± 30 ohms
Resistance

from one sensor to another.
Speed Sensor Ranges—Specification

Engine Cam Speed Sensor
(B5)—Resistance.............................................................. 2000 ± 30 ohms
Engine Crank Speed Sensor 9015A
(B4)—Resistance.............................................................. 3000 ± 30 ohms 20
97
2. Service ADVISOR can also be use to check sensor is

functioning properly with engine running. Connect to
machine and Perform Engine Sensor Check.
For machine location of sensor, See Engine Harness (W6)

Component Location Diagram (S.N. —590067). (Group
9015A-10.)
TX17994,0000346 –19–09SEP02–1/1

092005
PN=321
References
Engine Control Unit Pressure Sensors and

Solenoids Test (S.N. —590067)
SPECIFICATIONS
Pressure Sensor Ranges
Fuel Rail Pressure Sensor (B3) 11.7k ohms (Pins 1—2)
Resistance
Fuel Rail Pressure Sensor (B3) 13.4k ohms (Pins 2—3)
High Pressure Fuel Pump 3.2 ohms
Solenoids 1 and 2 (Y8 and Y9)
Resistance
1. A suspect pressure sensor or solenoid can be checked

by switching positions with a known good sensor or
solenoid. If the problem follows the suspect pressure
9015A sensor or solenoid, it has failed.
20
98 If the problem remains, the harness has failed.
2. To check a pressure sensor or solenoid using an

ohmmeter, remove it from the machine.

from one sensor or solenoid to another.
Pressure Sensor Ranges—Specification

Fuel Rail Pressure Sensor (B3)—
Resistance ............................................................ 11.7k ohms (Pins 1—2)
13.4k ohms (Pins 2—3)
High Pressure Fuel Pump
Solenoid 1 and 2 (Y8 and Y9)—
Resistance ................................................................................... 3.2 ohms
For machine location of sensor and solenoid, See Engine

Harness (W6) Component Location Diagram (S.N. —
590067). (Group 9015A-10.)
TX17994,000034A –19–25SEP02–1/1

092005
PN=322
References
Throttle Position Sensor Adjustment (S.N. —

590067)
SPECIFICATIONS
Throttle Position Sensor Reading 0.6 ± .1
Voltage—Pedal up
High Idle Engine Speed RPM 2350 ± 25
B14 Throttle Position Sensor sends signals to the Chassis

Control Unit. The Chassis Control Unit then sends the
throttle command to the engine controller unit by way of
the Controller Area Network (CAN) link.
See Analog Throttle in Measuring Throttle Position theory

of operation for more information. (CTM225.)
9015A
20
99

092005
PN=323
References
NOTE: The throttle position sensor is located under cab

on foot throttle assembly.
1. With the engine not running, loosen the screws holding

the sensor (A) to the bracket.
–UN–24MAR98
2. SERVICE ADVISOR™ can be use to check sensor is
functioning properly. Connect to machine and Perform
Loader Sensor Check.
T114497B
3. If not using Service ADVISOR, display Throttle (d 043)
voltage from diagnostic menu on monitor. See Monitor
Display Unit—Diagnostics Menu to access.
4. With engine off and accelerator pedal not pressed

down, turn sensor until voltage reading shown in
9015A
20 monitor basic display window is specification.
,100
Specification
Throttle Position Sensor
Reading—Voltage.................................................... 0.6 ± .1 with pedal up
5. Tighten sensor.
6. Start engine and press accelerator pedal all the way

down. The high idle rpm must be within specification.
Specification
High Idle Engine Speed—RPM .................................................. 2350 ± 25
SERVICE ADVISOR is a trademark of Deere & Company CED,TX17864,22 –19–11SEP02–2/2

092005
PN=324
References
Boom Height Kickout Adjustment (S.N. —

590067)
Boom height kickout position can be adjusted from cab

using the following procedure:
1. Position boom at the desired height.
2. Push up on BOOM switch on right console. Hold until

monitor beeps.
3. Lower boom.
4. Move loader control lever to boom raise detent position

and release.
9015A
Boom should raise to the set position. 20
,101
CED,TX04577,515 –19–05JUN02–1/1
Return-To-Carry Kickout Adjustment (S.N. —

590067)
Return to carry kickout position can be adjusted from the

cab using following procedure:
2. Push up on CARRY switch on right console. Hold until

monitor beeps.
3. Raise boom.
4. Move loader control lever to boom lower detent

position and release.
Boom should lower to the set position.
CED,TX04577,516 –19–05JUN02–1/1

092005
PN=325
References
Return-To-Dig Adjustment (S.N. —590067)
SPECIFICATIONS
Cap Screw Torque 121 N•m (89.0 lb-ft)
Air Gap Between Switch and Bar 5—8 mm (0.197— 0.315 in.)
Distance
Hex Screw Torque 75 N•m (55 lb-ft)
1. Raise boom adequately to allow clearance for full

bucket dump position.
IMPORTANT: The machine hydraulic system must be

at operating temperature before making
the adjustment. Cycle the cylinder
through full travel at leaset 4 times to
9015A ensure oil in the cylinder is warm.
20
,102 2. Move loader control lever to return-to-dig detent
IMPORTANT: Perform this step with the engine

operating between 1500 - 1700 rpm.
Continued on next page TX,20,SS3661 –19–10FEB05–1/2

092005
PN=326
References
–UN–26JUN00
9015A
20
,103
T131917
A—Air Gap Switch-To-Bar C—Cap Screws E—Hex Nuts F—Switch
B—Adjustable Bar D—Alignment Marks
3. After control lever returns to neutral, scribe a mark 6. Loosen hex nuts (E) to switch bracket. Adjust air
(D) on the switch bracket and adjustable bar (B) to gap (A) between switch and adjustable bar (B) to
align with each other. 5—8 mm (0.197— 0.315 in.). Torque hex nuts to
specification.
4. Position the boom and bucket in the desired
return-to-dig position. Stop engine. Specification
Air Gap Between Switch and
Bar—Distance ......................................... 5—8 mm (0.197—0.315 in.)
5. Loosen cap screws (C). Adjust bar to align marks Hex Screw—Torque ................................................. 75 N•m (55 lb-ft)
on switch bracket and end of bar. Torque cap
screws to specification.
Specification
Cap Screw—Torque ............................................ 121 N•m (89.0 lb-ft)
TX,20,SS3661 –19–10FEB05–2/2

092005
PN=327
References
Continuity Check For Sensors With Two

Wires (S.N. —590067)
This procedure checks if a failure of the wiring harness or

the sensor is causing a two wire sensor service code to
be generated. Use the monitor or SERVICE ADVISOR™
system. See SERVICE ADVISOR system Computer
Connection for information on connecting to J-Series
loaders (S.N. —590067).
Performing Two-Wire Sensor Check
1. Record and clear service codes. See Diagnostic

Trouble Codes (DTC) (S.N. —590067) in Group
9005-10.
9015A
20
,104
SERVICE ADVISOR is a trademark of Deere & Company CED,TX17994,362 –19–27JUL00–1/2
2. With key switch OFF, disconnect suspected sensor

wiring harness connector. Connect a jumper wire
between the wires in the harness connector.
3. Start engine and run for several seconds. Stop engine.
–19–21OCT96
4. Record all service codes as in Step 1 above.
5. If a new service code appears, a failed sensor is

indicated. (You created the new service code when
T104537
you connect the jumper wire, proving the harness is
OK.)
6. If a new service code does not appear, a failed

harness or controller is indicated. (The harness cannot
send the new service code to the CCU)
CED,TX17994,362 –19–27JUL00–2/2

092005
PN=328
References
Continuity Check For Sensors With Three

Wires (S.N. —590067)

the sensor is causing a three wire sensor service code to
be generated. Use the monitor or SERVICE ADVISOR™
system. See SERVICE ADVISOR system Computer
Connection for information on connecting to J-Series
loaders (S.N. —590067).
Performing Three-Wire Sensor Check
1. Record and clear service codes. See Checking And

Clearing Diagnostic Service Codes From Monitor in
Group 9005-10.
9015A
2. With key switch OFF disconnect the suspected sensor 20
wiring harness connector. If the original service code ,105
was “Short to Power” connect a jumper wire between
the sensing wire and the ground wire in the wiring
harness connector.
SERVICE ADVISOR is a trademark of Deere & Company CED,TX17994,363 –19–27JUL00–1/2
If the original service code was “Short to Ground” connect

a jumper wire between the sensing wire and the power
wire in the wiring harness connector.
3. Start engine and run several seconds. Stop engine.
4. Press Next to display the next service code. Record all

service codes.
5. Record all service codes as in Step 1 above.
6. If a new service code appears, “Short-to-Ground” or

“Short-to-Power”, a failed sensor is indicated. (You
created the new service code when you connected the
jumper wire, proving the harness is OK.)
7. If a new service code does not appear, a failed

send the new service code to the CCU)
–19–21OCT96
T104538
CED,TX17994,363 –19–27JUL00–2/2

092005
PN=329
References
Replace METRI-PACK™ Connectors (S.N. —

590067)
1. A small locking tab is located inside of the

METRI-PACK™ connector. Use a small screwdriver to
move tab outward to the first detent position; the tab
will “click.”
2. Slide JDG939 METRI-PACK™ Extractor Tool into

connector body until it is positioned over terminal
contact.
3. Gently pull wire out of connector body.
IMPORTANT: Install contact in proper location using

9015A correct size grommet.
20
,106 4. Push contact straight into connector body until positive
stop is felt.
5. Pull on wire slightly to be certain contact is locked in

place.
6. Transfer remaining wires to correct terminal in new

connector.
7. Use a small screwdriver to move tab inward to the first

detent position; the tab will “click” and lock the wires in
the connector body.
METRI-PACK is a trademark of Packard Electric TX,16,1111112 –19–28MAY98–1/1

092005
PN=330
References
Replace DEUTSCH™ Connectors (S.N. —

590067)
1. Select correct size extractor tool for size of wire to be

removed:
–UN–23AUG88
1. JDG361 Extractor Tool for 12 to 14 gauge wire.
2. JDG362 Extractor Tool for 16 to 18 gauge wire.
3. JDG363 Extractor Tool for 20 gauge wire.
TS0124
2. Start correct size extractor tool over wire at handle (A).
3. Slide extractor tool rearward along wire until tool tip

snaps onto wire.
IMPORTANT: Do NOT twist tool when inserting in 9015A

connector. 20
,107
–UN–23AUG88
4. Slide extractor tool along wire into connector body until
it is positioned over terminal contact.
A—Handle
TS120
DEUTSCH is a trademark of Deutsch Co. TX,1674,111990 –19–28MAY98–1/2
5. Pull wire out of connector body, using extractor tool.

correct size grommet.
6. Push contact straight into connector body until positive

–UN–23AUG88
stop is felt.

place.
TS122

connector.
TX,1674,111990 –19–28MAY98–2/2

092005
PN=331
References
Install DEUTSCH™ Contact (S.N. —590067)
1. Strip 6 mm (1/4 in.) insulation from wire.
2. Adjust selector (A) on JDG360 Crimper for correct wire

size.
–UN–23AUG88
3. Loosen lock nut (B) and turn adjusting screw (C) in
until it stops.
TS117
A—Selector
B—Lock Nut
C—Adjusting Screw
9015A
20
,108
DEUTSCH is a trademark of Deutsch Co. TX,16,1111115 –19–28MAY98–1/4
IMPORTANT: Select proper size contact “sleeve” or

“pin” to fit connector body.
4. Insert contact (A) and turn adjusting screw (D) until

contact is flush with cover (B).
–UN–23AUG88
5. Tighten lock nut (C).
A—Contact
B—Cover
TS0134
C—Lock Nut
D—Adjusting Screw
TX,16,1111115 –19–28MAY98–2/4
IMPORTANT: Contact must remain centered between

indentors while crimping.
6. Insert wire in contact and crimp until handle touches

stop.
–UN–23AUG88
TS118
Continued on next page TX,16,1111115 –19–28MAY98–3/4

092005
PN=332
References
7. Release handle and remove contact.
IMPORTANT: If all wire strands are not crimped into

contact, cut off wire at contact and
repeat contact installation procedures.
–UN–23AUG88
NOTE: Readjust crimping tool for each crimping
procedure.
8. Inspect contact to be certain all wires are in crimped
TS0135
barrel.
9015A
20
,109
TX,16,1111115 –19–28MAY98–4/4
Replace WEATHER PACK™ Connectors

(S.N. —590067)
IMPORTANT: Identify wire color locations with

connector terminal letters.
–UN–23AUG88
1. Open connector body (A).
A—Connector Body
WEATHER PACK is a trademark of Packard Electric. TS0127

TX,16,QQ9343 –19–28MAY98–1/4
2. Insert JDG364 Extraction Tool over terminal contact in

connector body.
–UN–23AUG88
TS0128
Continued on next page TX,16,QQ9343 –19–28MAY98–2/4

092005
PN=333
References
3. Hold extractor tool fully seated and pull wire from

connector body.
NOTE: If terminal can not be removed, insert wire or nail

through extractor tool handle and push terminal
contact from connector.
–UN–23AUG88
TS0129
TX,16,QQ9343 –19–28MAY98–3/4
IMPORTANT: Carefully spread contact lances to

9015A assure good seating in connector body.
20
,110 NOTE: Connector bodies are “keyed” for proper contact
mating. Be sure contacts are in proper alignment.
–UN–23AUG88
4. Push contact into new connector body until fully
seated.
TS0130
place.

connector.
7. Close connector body.
TX,16,QQ9343 –19–28MAY98–4/4
Install WEATHER PACK™ Contact (S.N. —

590067)
NOTE: Cable seals are color coded for three sizes of

wire:
–UN–23AUG88
• Green - 18 to 20 gauge wire

• Gray - 14 to 16 gauge wire
• Blue - 10 to 12 gauge wire
TS0136
1. Slip correct size cable seal on wire.
WEATHER PACK is a trademark of Packard Electric. Continued on next page TX,1674,111993 –19–28MAY98–1/3

092005
PN=334
References
2. Strip insulation from wire to expose 6 mm (1/4 in.) and

align cable seal with edge of insulation.
NOTE: Contacts have numbered identification for two

sizes of wire:
–UN–02NOV94
1. #15 for 14 to 16 gauge wire
2. #19 for 18 to 20 gauge wire
3. Put proper size contact on wire and crimp in place with
TS1623
a “W” type crimp, using JDG783 Crimping Tool
9015A
20
,111
TX,1674,111993 –19–28MAY98–2/3
4. Secure cable seal to contact as shown, using JDG783

Crimping Tool.
IMPORTANT: Proper contact installation for “sleeve”

(A) and “pin” (B) is shown.
–UN–02DEC88
A—Sleeve
B—Pin
TS0139
TX,1674,111993 –19–28MAY98–3/3
Remove And Install Transmission Control

Valve Connector Body (S.N. —590067)
1. A small locking tab is located inside of the connector.

Use a small screwdriver (B) to move tab (A) outward to –UN–01NOV96
the first detent position; the tab will “click.”
A—Tab
B—Screwdriver
T104764B
Continued on next page TX,16,RP3113 –19–28MAY98–1/3

092005
PN=335
References
2. Slide JDG140 METRIMATE™ Extractor Tool (B) into

connector body until it is positioned over terminal
contact.
3. Push on end of extractor tool (B) and gently pull wire
–UN–01NOV96
(A) out of connector body.

T104763B
stop is felt.
A—Wire
5. Pull on wire slightly to be certain contact is locked in B—Extractor Tool
place.
9015A
20 6. Transfer remaining wires to correct terminal in new
,112 connector.
METRIMATE is a trademark of AMP Inc. TX,16,RP3113 –19–28MAY98–2/3
7. Use a small screwdriver (B) to move tab (A) inward to

the first detent position; the tab will “click” and lock the
wires in the connector body.
A—Tab
–UN–01NOV96
B—Screwdriver
T104764B
TX,16,RP3113 –19–28MAY98–3/3
Install Transmission Control Valve Connector

Contact (S.N. —590067)

–UN–23AUG88

TS0136
Continued on next page TX,16,RP3112 –19–28MAY98–1/2

092005
PN=336
References
3. Put contact on wire and insert into crimper at location

(D) and crimp on contact at location (B) using JDG707
crimping tool.
4. Secure cable seal to contact by crimping at location (A)

on contact and crimp at location (C) on JDG707
–UN–09JAN97
crimping tool.
A—Contact Location
T105879B
B—Contact Location
C—Crimper Location
D—Crimper Location
9015A
20
,113
TX,16,RP3112 –19–28MAY98–2/2

092005
PN=337
References
Crimper Tool For Transmission Control Unit Connector—Operation (S.N. —590067)
9015A
20
,114
–UN–28JUL98
T116613
A—Stationary Jaw D—Frame G—Ratchet Adjustment Wheel J—Front of Tool (Locator Side)
B—Back of Tool (Wire Side) E—Stationary Handle H—Moving Jaw K—Locator Assembly
C—Pivot Pin F—Moving Handle I—Die Assembly
The Crimper Tool is used to crimp wires for the junior Attached to the outside of the frame is a locator
timer contacts and the micro timer contacts of the assembly, which contains a locator, a spring retainer,
transmission controller unit connector. The tool has a and a contact support.
frame with a stationary jaw and handle, a moving jaw,
a moving handle and an adjustable ratchet that Die retaining pins and die retaining screws are used to
ensures full contact crimping. The tool frame holds a position and secure the dies in the tool frame. A nut is
die assembly with two crimping sections. used on the upper die retaining screw to hold the
locator assembly in place.
The die assembly features a wire anvil, an insulation
anvil, a wire crimper, and an insulation crimper.
CED,OUOE003,1033 –19–24JUL98–1/1

092005
PN=338
References
Crimper Tool For Transmission Control Unit Connector—Remove And Install Die Set
(S.N. —590067)
9015A
20
,115
–UN–28JUL98
T116614
A—Nut E—Die Retaining Screws H—Wire Anvil K—Chamfer
B—Locator Assembly F—Chamfer I—Offset L—Locator
C—Tool Frame G—Insulation Anvil J—Wire Crimper M—Insulation Crimper
D—Die Retaining Pins
1. Open the tool handles and remove the two die surfaces face outward, when mounted in the
retaining screws (E) from the tool jaws. stationary jaw of the tool frame.
2. Place the wire anvil (H) and insulation anvil (G) so 6. Insert the two die retaining pins.
that their chamfered sides and their marked
surfaces face outward, when mounted in the 7. Insert the long die retaining screw through the jaw
moving jaw of the tool frame. and through both crimper dies. Tighten the screw
just enough to hold the dies in place. DO NOT
3. Insert the two die retaining pins (D). tighten the screw completely at this time.
4. Insert the short die retaining screw through the jaw 8. Carefully close the tool handles, making sure that
and through both anvil dies, and tighten the screw the anvils and crimpers align properly. Continue
just enough to hold the dies in place. DO NOT closing the tool handles until the ratchet in the tool
tighten the screw completely at this time. frame has engaged sufficiently to hold the anvils
and crimpers in place, then tighten both die
5. Place the wire crimper (J) and insulation crimper retaining screws.
(M) so that their chamfered sides and their marked
Continued on next page CED,OUOE003,1034 –19–24JUL98–1/2

092005
PN=339
References
9. Place the locator assembly over the end of the long 11. To disassemble, close the tool handles until the
screw, and position the locator assembly against ratchet releases. Remove the nut, the locator
the side of the tool jaw. assembly, the two die retaining screws, and the
four die retaining pins. Slide the anvils and
10. Place the nut onto the end of the long screw and crimpers out of the tool jaws.
tighten the nut enough to hold the locator to slide
up and down.
CED,OUOE003,1034 –19–24JUL98–2/2
9015A
20
,116

092005
PN=340
References

Connector—Contact Support Adjustment
(S.N. —590067)
(S.N. —590067)
NOTE: The contact support is preset prior to shipment,

but minor adjustment may be necessary.
1. Make a sample crimp and determine if the contact is

straight, bending upward, or bending downward.
2. If adjustment is required, loosen the screw that holds

the contact support onto the locator assembly.
NOTE: The ratchet has detents that create audible clicks 9015A
as the tool handles are closed. 20
,117
3. Place a contact with wire into the proper nest and
close the tool handles until the ratchet reaches the
sixth click, or until the contact support touches the
contact.
4. Slightly loosen the nut that holds the locator assembly

onto the tool frame.
5. Move the contact support as required to eliminate the

bending of the contact.
6. Tighten the nut and close the handles until the ratchet
releases.
7. Remove and inspect the contact.
8. Make another sample crimp. If the contact is straight,

tighten the contact support screw. If the contact is still
being bent during crimping, repeat the adjustment
procedure.
TX,16,1111104 –19–28MAY98–1/1

092005
PN=341
References

Connector—Crimping Procedure (S.N. —
590067)
IMPORTANT: Verify crimp height before using the

tool to crimp desired contacts and wire
–UN–21JUL98
sizes. See Crimp Height Inspection and
Crimp Height Adjustment in this group.
T112336C
1. Select wire of the specified size and insulation
diameter. Strip the wire to length indicated. Do not nick
or cut wire strands.
Micro Timer Contact Slot
Contact Size (AWG) Wire Insulation Strip Length

Diameter
9015A Junior Timer 0.5—1.0 mm 2.0 mm (0.079 4.7 mm (0.185

20 Contacts in.) Max. in.)
,118 Micro Timer 0.5—1.0 mm 1.6 mm (0.063 4.3 mm (0.170
Contacts in.) Max. in.)
–UN–21JUL98
A—Contact Slot
T112335C
Junior Timer Contact Slot

092005
PN=342
References
9015A
20
,119
–UN–28JUL98
T116615
A—Adjustment Screw for C—Locator F—Micro Timer Slot H—Locator in Wire Stop Slot
Contact Support D—Wire G—Contact I—Wire Inserted to Stop
B—Contact Support E—Junior Timer Slot
2. Hold the tool so that the back (wire side) is facing top of the tool. Place the contact up into the nest so
you. Squeeze tool handles together and allow them that the movable locator drops into the slot in the
to open fully. contact. Butt the front end of the wire barrel against
the movable locator.
3. Holding the contact by the mating end, insert the
contact—insulation barrel first—through the front of 5. Hold the contact in position and squeeze the tool
the tool and into the appropriate crimp section. handles together until ratchet engages sufficiently to
hold the contact in position. Do NOT deform
IMPORTANT: Make sure that both sides of the insulation barrel or wire barrel.
insulation barrel are started evenly
into the crimping section. Do NOT 6. Insert stripped wire into contact insulation and wire
attempt to crimp an improperly barrels until it is butted against the wire stop.
positioned contact.
7. Hold the wire in place: squeeze tool handles
4. Position the contact so that the mating end of the together until ratchet releases. Allow tool handles to
contact is on the locator side of the tool, so that the open and remove crimped contact.
open “U” of the wire and insulation barrels face the

092005
PN=343
References
NOTE: The crimped contact may stick in the crimping 8. Check the contact crimp height. If necessary, adjust
area. It can be easily removed by pushing the crimp height. See Crimp Height Inspection and
downward on the top of the locator. Crimp Height Adjustment.
CED,OUOE003,1035 –19–24JUL98–3/3

Connector—Crimp Height Inspection (S.N. —
590067)
1. Use a crimp height comparator to measure the wire

barrel crimp height as shown.
–UN–21NOV97
WIRE SIZE AWG CRIMP SECTION CRIMP HEIGHT DIM. (C)
9015A (MAX) (WIRE SIZE AND TOLERANCE (±)
20 MARKING)
T112327
,120 1.0 mm Junior 1.27 ± 0.051 mm
(0.0500 ± 0.0020 in.)
1.0 mm Micro 1.20 ± 0.051 mm
(0.0472 ± 0.0020 in.) A—Position Point on Center of Wire Barrel
Opposite Seam
B—Modified Anvil
2. If the crimp height conforms to specifications, the tool C—Dimension
is considered dimensionally correct.
If not, the tool must be adjusted. See Crimp Height

Adjustment.
TX,16,1111106 –19–28MAY98–1/1

092005
PN=344
References

Connector—Crimp Height Adjustment
(S.N. —590067)
Apply a load to the pivoting handle until the ratchet

releases. The force at approximately 1 3/4 in. from handle
ends should vary between 5—35 lbs. Depending on the
style/type and size of contact and/or wire size.
The style type of contact crimped determines the level of

handle pre-load, with larger contacts requiring higher
pre-loads for properly completed crimps.
To adjust the tool to obtain the proper force values, use

the following procedure:
9015A
1. Open handle and remove cam locking screw (B) with a 20
1/8 in. hex wrench. ,121
2. Rotate cam (A) counterclockwise to increase handle
–UN–28JUL98
load or clockwise to decrease handle load.
3. Position odd numbers on cam in locking screw hole

adjacent to the letter “L” and even numbers adjacent to
T116616
the letter “T”.
4. Lock the cam at the desired handle load setting and

A—Eccentric Cam
measure force. B—Lock Screw
5. Continue adjustment if necessary.
NOTE: If over crimping of contacts results, adjust ratchet

release force to 15—30 lbs.
CED,OUOE003,1036 –19–24JUL98–1/1

092005
PN=345
References
Replace Transmission Control Unit

Connector Terminals (S.N. —590067)
The transmission controller unit connector has two size

terminals:
• Junior Timer Contacts (Large)—Use JDG1177 Extractor

• Micro Timer Contacts (Small)—Use FKM10457
Extractor
1. Insert extractor (A) into front (terminal side) of

connector (C). Use extractor to press in the locking
tabs of terminal.
2. Remove extraction tool and pull wire with terminal (B)

9015A through rear of connector.
20
,122 3. Install new terminal into rear of connector, pushing it in
until it stops. Locking tabs must be properly lined up
with the socket.
–UN–01DEC97
4. Pull on wire slightly to be certain terminal is locked in
place.
T112380B
A—Extractor
B—Wire
C—Connector
TX,16,1111113 –19–28MAY98–1/1

092005
PN=346
References
Replace Chassis Control Unit Connector

1. Remove extraction tool (1) from the loading side of

connector.
2. Insert blade of extraction tool into locking tabs (2) of

secondary lock (3). Rotate tool away from the
connector to pry one side of the secondary lock out of
the locked position. Repeat this step for the other
locking tab.
NOTE: After unlocking one side of the secondary lock, a

screw driver or similar device may need to be
–UN–29JUN00
used to hold it in the unlocked position while
unlocking the second locking tab. 9015A
20
,123
T132105B
1—Extraction Tool
2—Secondary Lock Locking Tabs
3—Secondary Lock
TX,16,1111114 –19–17APR01–1/3
3. Remove secondary lock (3).
3—Secondary Lock
–UN–29JUN00
T132301B
Continued on next page TX,16,1111114 –19–17APR01–2/3

092005
PN=347
References
4. Insert pointed side of extraction tool into the contact

cavity so that the flat side of tool faces secondary lock
cavity (4). This will release the primary contact locking
tab.
5. Gently pull wire out of the connector.
–UN–29JUN00
6. Repair/Replace terminals as necessary using
procedure in this group. (See Install CINCH Contact.)
T132107B
7. Insert contact and wire into connector until it clicks.
8. Install secondary lock.
9015A
20
,124
TX,16,1111114 –19–17APR01–3/3

092005
PN=348
References
Reprogram Monitor Display Unit (S.N. —590067)
(S.N. —590067) scroll through the tire size options until the desired
size is displayed. Then press SELECT. Press
When either the monitor display unit (MDU), BACK to “S 03.”
Transmission Control Unit (TCU), or Chassis Control
Unit (CCU) is replaced or exchanged from another 5. Press NEXT until “S 06” displays. At the Service
unit, the monitor display unit must be reprogrammed. Diagnostics Menu “S 06” Enable Options mode,
Reprogramming is done in the Monitor Display Unit press SELECT to display “S 061” option. Press
Service Diagnostics Menu using the following SELECT again to enable (“On”) or disable (“Off”)
procedure. each appropriate option installed on the machine. If
reprogramming of the machine model has been
NOTE: See Monitor Display Unit—Service Menu to successful, all options in this menu will be turned
access Service Menu. (Group 9015A-15.) “Off”. These must be reset to “On.” If an option
already shows “On” cycle it to “Off” then back to
1. Turn key switch On. At the User Diagnostics Menu “On.”
9015A
(d 01) Fault Codes mode, scroll through the fault 20
codes until “F End” shows in the display window. 6. “S 065” should be “On” for 744J machines. When ,125
Press and hold SELECT at least 6 seconds until “S” “S 065” is “On,” Fault Code “F0478” will be
is displayed, which indicates Service Diagnostics displayed in the User Diagnostics Menu—Fault
Menu. Codes (d 01) mode. Clear this fault code; press and
hold SELECT for three seconds while fault is
NOTE: The park brake must be set and the shifter displayed.
switch must be in Neutral for the
reprogramming procedure. NOTE: When the monitor display unit is
reprogrammed after a Transmission Control
2. Apply park brake. Move shifter lever to Neutral Unit (TCU) replacement, Fault Code “F1699”
position. Press SELECT, and the Service Menu “S may be displayed.
01” Machine Model mode will be displayed.
7. If Fault Code “F1699” is displayed in the
3. At the “S 01” display, press SELECT again, to see Diagnostics Menu—Fault Codes (d 01) mode, clear
the currently configured model. Press NEXT to the fault. Press and hold SELECT for three seconds
scroll through the machine models until the desired while fault is displayed.
model is displayed. Then press SELECT. If
reprogramming is successful, dOnE will be IMPORTANT: After reprogramming, key switch
displayed. If programming is not successful, FAIL must be turned “Off” then back “On”
will be displayed, and procedure must be repeated. before the TCU will allow
Press BACK to “S 01.” transmission to shift into gear.
4. Press NEXT to “S 03.” At the Service Menu “S 03” 8. Reprogramming is complete. After enabling all the
Tire Size mode, press SELECT and the currently appropriate options, press MENU key to return to
configured tire size is displayed. Press NEXT to Normal Gear LCD display. Turn key switch Off.
TX,16,111501 –19–19NOV04–1/1

092005
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References
Install CINCH™ Contact (S.N. —590067)
9015A
20
,126
–UN–14FEB01
T138057
A—Top of Tool D—Wire F—Junior Timer Slot I—Wire Tab
B—Contact Support E—Micro Timer Slot G—Contact J—Insulation Tab
C—Locator
1. Hold JDG708 crimping tool so that the tool is facing 3. Hold the contact in position and squeeze the tool
you as shown (left side of graphic). Squeeze tool handles together until ratchet engages sufficiently to
handles together and allow them to open fully. hold the contact in position. Do NOT deform wire
and insulation tabs (I and J).
IMPORTANT: Make sure that both sides of the
insulation barrel are started evenly 4. Insert stripped wire into contact insulation and wire
into the crimping section. Do NOT tabs until it is butted against locator (C).
attempt to crimp an improperly
positioned contact. 5. Hold the wire in place. Squeeze tool handles
together until ratchet releases. Allow tool handles to
2. Position the contact so that the mating end of the open and remove crimped contact.
contact (G) is on the locator side of the tool (C).
Wire and insulation tabs (I and J) should point to 6. Install contact into connector.
top of tool (A). Butt wire tab (I) against the movable
locator (C).
CINCH is a trademark of the Cinch Co. CED,TX17994,330 –18–29JUN00–1/1

092005
PN=350
References
Remove Connector Body From Blade

1. Depress locking tang (A) on terminal, using a small

screw driver. Slide connector body off.
–UN–23AUG88
2. Be sure to bend locking tang back to its original
position (B) before installing connector body.
RW4218
A—Locking Tang
B—Locking Tang Original Position
9015A
20
,127
TX,1674,111994 –19–28MAY98–1/1
Fuse Block Terminal Remove and Install

(S.N. —590067)
Use small screw driver to depress each locking tang (A)

on terminal. Pull terminal out of fuse block.
Be sure to bend locking tangs back to original position (B)

before installing in fuse block.
A—Locking Tang
B—Locking Tang Original Position
–UN–14DEC91
T7670AC
TX,1674,111995 –19–28MAY98–1/1

092005
PN=351
References
Pressure Switches Remove and Install

(S.N. —590067)
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
–UN–23AUG88
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
X9811
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
If an accident occurs, see a doctor immediately.

9015A Any fluid injected into the skin must be
20
surgically removed within a few hours or
,128
gangrene may result. Doctors unfamiliar with
this type of injury should reference a
knowledgeable medical source. Such
information is available from Deere & Company
Medical Department in Moline, Illinois, U.S.A.
Before removing any pressure switch, operate all

hydraulic control valves to relieve hydraulic pressure.
With boom raised slightly, turn ignition switch to on

position. Cycle the ride control switch from off to on
(center position). Boom will jump up unexpectedly if ride
control accumulator is energized. Press boom enable
switch and move the control lever into the float position
and hold for 5 seconds.
Push brake pedal at least 40 times to discharge brake

accumulators.
TX,1674,MM3113 –19–13OCT98–1/1

092005
PN=352
References
Boom Down, Differential Lock, and Pilot

Enable Solenoid Valve Remove And Install
(S.N. —590067)
1. Discharge ride control accumulator to release hydraulic

pressure from loader and pilot circuit. (See Ride
–UN–23AUG88
Control Accumulator Safety in this group).
2. Disconnect electrical connector.
X9811
3. Remove parts (C—E).
4. Remove parts (F—K). Plug opening to prevent dirt

from entering manifold.
5. Inspect for dirty, worn or damaged parts. Check that 9015A

spool inside solenoid valve moves freely. If spool does 20
not move freely or if valve looks worn or damaged, ,129
–UN–12JUN98
replace complete solenoid assembly.
6. Install solenoid valve using new O-rings and backup

rings.
T115830
7. Install parts (C—K). Tighten nut (C).
Specification
Differential Lock Solenoid Valve
Retaining Nut—Torque ..................................................... 7 N•m (62 lb-in.)
8. Connect electrical connector.
–UN–09NOV92
A—Differential Lock Solenoid
B—Pressure Reducing Manifold
C—Nut
D—ID Plate
E—Coil
T7751LI
F—Solenoid Valve
G—O-Ring
H—Backup Ring
I—O-Ring
J—O-Ring
K—Backup Ring
CED,OUOE002,1675 –19–12AUG02–1/1

092005
PN=353
References
9015A
20
,130

092005
PN=354
Section 9015B
Electrical System—644J And 724J (S.N.
590068— )
Contents
Page Page
Group 05—System Information Rear Frame Harness (W13) Component

Electrical Diagram Information (S.N. Location (S.N. 590068— ) . . . . . . . . . . 9015B-10-64
590068— ). . . . . . . . . . . . . . . . . . . . . . . 9015B-05-2 Rear Frame Harness (W13) Wiring
Diagram (S.N. 590068— ) . . . . . . . . . . 9015B-10-66
Group 10—System Diagrams Cab Roof Harness (W19) Component
Fuse and Relay Specifications (S.N. Location (S.N. 590068— ) . . . . . . . . . . 9015B-10-68
590068— ). . . . . . . . . . . . . . . . . . . . . . . 9015B-10-2 Cab Roof Harness (W19) Wiring Diagram
System Functional Schematic, Wiring (S.N. 590068— ) . . . . . . . . . . . . . . . . . 9015B-10-70
Diagram and Component Location Blower and A/C Harness (W20)
Legend (S.N. 590068— ) . . . . . . . . . . . . 9015B-10-4 Component Location (S.N. 590068—
System Functional Schematic and Section ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015B-10-72
Legend (S.N. 590068— ) . . . . . . . . . . . 9015B-10-14 Blower and A/C (W20) Wiring Diagram (S.N. 9015B
Loader Frame Harness (W2) Component 590068— ). . . . . . . . . . . . . . . . . . . . . . 9015B-10-74
Location (S.N. 590068— ) . . . . . . . . . . 9015B-10-18 Radio Harness (W34) Component
Loader Frame Harness (W2) Wiring Location (S.N. 590068— ) . . . . . . . . . . 9015B-10-76
Diagram (S.N. 590068— ) . . . . . . . . . . 9015B-10-20 Radio Harness (W34) Wiring Diagram (S.N.
Load Center Harness (W3) Component 590068— ). . . . . . . . . . . . . . . . . . . . . . 9015B-10-78
Location (S.N. 590068— ) . . . . . . . . . . 9015B-10-22
Load Center Harness (W3) Wiring Group 15—Sub-System Diagnostics
Diagram (S.N. 590068— ) . . . . . . . . . . 9015B-10-24 Starting and Charging Circuit Theory of
Front Console Harness (W4) Component Operation (S.N. 590068— ) . . . . . . . . . . 9015B-15-1
Location (S.N. 590068— ) . . . . . . . . . . 9015B-10-38
Controller Area Network (CAN) Theory of
Front Console Harness (W4) Wiring
Operation (S.N. 590068— ) . . . . . . . . . . 9015B-15-3
Diagram (S.N. 590068— ) . . . . . . . . . . 9015B-10-40
Engine Control Unit (ECU) Circuit Theory
Engine Frame Harness (W5) Component
of Operation (S.N. 590068— ) . . . . . . . . 9015B-15-5
Location (S.N. 590068— ) . . . . . . . . . . 9015B-10-42
Flex Load Controller (FLC) Circuit Theory
Engine Frame Harness (W5) Wiring
of Operation (S.N. 590068— ) . . . . . . . . 9015B-15-9
Diagram (S.N. 590068— ) . . . . . . . . . . 9015B-10-44
Transmission Control Unit (TCU) Circuit
Engine Harness (W6) Component
Theory of Operation (S.N. 590068—
Location (S.N. 590068— ) . . . . . . . . . . 9015B-10-46
Engine Harness (W6) Wiring Diagram (S.N. ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015B-15-27
590068— ). . . . . . . . . . . . . . . . . . . . . . 9015B-10-50 CAN Monitor Unit (CMU) Circuit Theory of
Engine Air Heater Harness (W7) Operation (S.N. 590068— ) . . . . . . . . . 9015B-15-32
Component Location (S.N. 590068—
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015B-10-52 Group 20—References
Engine Air Heater Harness (W7) Wiring Diagnostic Trouble Codes Quick
Diagram (S.N. 590068— ) . . . . . . . . . . 9015B-10-54 Reference List (S.N. 590068— ) . . . . . . 9015B-20-1
Ride Control Harness (W9) Component CAN Monitor Unit (CMU) Diagnostic
Location (S.N. 590068— ) . . . . . . . . . . 9015B-10-56 Trouble Codes (S.N. 590068— ) . . . . . . 9015B-20-6
Ride Control Harness (W9) Wiring Flex Load Controller (FLC) Diagnostic
Diagram (S.N. 590068— ) . . . . . . . . . . 9015B-10-58 Trouble Codes (S.N. 590068— ) . . . . . . 9015B-20-8
Transmission Harness (W10) Component Sealed Switch Module (SSM) Diagnostic
Location (S.N. 590068— ) . . . . . . . . . . 9015B-10-60 Trouble Codes (S.N. 590068— ) . . . . . 9015B-20-22
Transmission Harness (W10) Wiring
Diagram (S.N. 590068— ) . . . . . . . . . . 9015B-10-62 Continued on next page
TM2075 (03MAR05) 9015B-1 644J and 724J Loader

092005
PN=1
Contents
Page Page
Transmission Control Unit (TCU) Transmission Control Unit (TCU) Remove

Diagnostic Trouble Codes (S.N. 590068— and Install (S.N. 590068— ) . . . . . . . . 9015B-20-83
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015B-20-26 Sealed Switch Module (SSM) Remove
Engine Control Unit (ECU) Diagnostic and Install (S.N. 590068— ) . . . . . . . . 9015B-20-84
Trouble Codes (S.N. 590068— ) . . . . . 9015B-20-39 CAN Monitor Unit (CMU) Remove and
Flex Load Controller (FLC) Fault Install (S.N. 590068— ) . . . . . . . . . . . . 9015B-20-85
Exceptions (S.N. 590068— ) . . . . . . . . 9015B-20-47 Reprogram CAN Monitor Unit (CMU) S.N.
Check Battery Electrolyte Level and 590068—) . . . . . . . . . . . . . . . . . . . . . . 9015B-20-85
Terminals (S.N. 590068— ) . . . . . . . . . 9015B-20-50 Electronic Controller Reconfiguration (S.N.
Procedure For Testing Batteries (S.N. 590068 —). . . . . . . . . . . . . . . . . . . . . . 9015B-20-87
590068— ). . . . . . . . . . . . . . . . . . . . . . 9015B-20-52
Electrical Component Specifications (S.N.
590068— ). . . . . . . . . . . . . . . . . . . . . . 9015B-20-54
Transmission Control Valve Solenoid
Check (S.N. 590068— ). . . . . . . . . . . . 9015B-20-59
Clutch Cut-Off Sensor Check and
Adjustment (S.N. 590068— ) . . . . . . . . 9015B-20-60
Boom Height Kickout/Return-to-Carry
Adjustment (S.N. 590068— ) . . . . . . . . 9015B-20-61
9015B
Return-to-Dig Adjustment (S.N. 590068—
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015B-20-62
Sensor Circuitry Check (S.N. 590068—
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015B-20-63
Diagnostic Trouble Codes—After Machine
Repair (S.N. 590068— ) . . . . . . . . . . . 9015B-20-65
Change Back-Up Alarm Volume (S.N.
590068— ). . . . . . . . . . . . . . . . . . . . . . 9015B-20-65
Remove and Install Pressure Switches (S.N.
590068— ). . . . . . . . . . . . . . . . . . . . . . 9015B-20-66
Replace METRI-PACK™ Connectors (S.N.
590068— ). . . . . . . . . . . . . . . . . . . . . . 9015B-20-67
Install METRI-PACK™ Contact (S.N.
590068— ). . . . . . . . . . . . . . . . . . . . . . 9015B-20-68
Replace DEUTSCH™ Connectors (S.N.
590068— ). . . . . . . . . . . . . . . . . . . . . . 9015B-20-69
Install DEUTSCH™ Contact (S.N.
590068— ). . . . . . . . . . . . . . . . . . . . . . 9015B-20-71
Replace WEATHER PACK™ Connector (S.N.
590068— ). . . . . . . . . . . . . . . . . . . . . . 9015B-20-72
Install WEATHER PACK™ Contact (S.N.
590068— ). . . . . . . . . . . . . . . . . . . . . . 9015B-20-73
Replace CINCH™ Connectors (S.N.
590068— ). . . . . . . . . . . . . . . . . . . . . . 9015B-20-74
Install CINCH™ Contact (S.N. 590068—
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015B-20-76
Repair 32 and 48 Way CINCH™
Connectors (S.N. 590068— ). . . . . . . . 9015B-20-77
Remove Connector Body from Blade
Terminals (S.N. 590068— ) . . . . . . . . . 9015B-20-80
Engine Control Unit (ECU) Remove and
Install (S.N. 590068— ) . . . . . . . . . . . . 9015B-20-80
Flex Load Controller (FLC) Remove and
Install (S.N. 590068— ) . . . . . . . . . . . . 9015B-20-82
TM2075 (03MAR05) 9015B-2 644J and 724J Loader

092005
PN=2
Group 05
System Information
9015B
05
1
TM2075 (03MAR05) 9015B-05-1 644J and 724J Loader

092005
PN=357
System Information
Electrical Diagram Information (S.N. 590068— )
9015B
05
2
–UN–29FEB00
T128818

092005
PN=358
System Information
1—Continuity Chart 4—Wire Identification 7—Section Number 10—Component Schematic

2—Power Wires 5—Ground Wires 8—Component Name Symbol
3—Routing Location 6—Circuit Name 9—Component Identification
Information Number
NOTE: All System Functional Schematics, Circuit Each electrical component is shown by a schematic
Schematics, and Wiring Diagrams are shown symbol (10), the component name (8), and a
with key switch in the off position. component identification number (9). A component
identification number and name will remain the same
System Functional Schematic Diagram throughout the Operation and Test Technical Manual.
This will allow for easy cross-referencing of all
The System Functional Schematic is made up of electrical drawings (Schematics, Wiring Diagrams, and
sections which contain one or more Subsystem Component Location). A continuity chart (1) is included
Functional Schematics laid out side by side in a logical for each multi-terminal switch.
sequence of related functions. Each subsystem is a
major group of components like starting components or Routing location information (3) is presented to let the
charging components. Each section of the System reader know when a wire is connected to a component
Functional Schematic is assigned a number (7) and a in another section. TO and FROM statements identify
name (6) that reflects a group of components. The when power is going “To” or coming “From” a
System Functional Schematic is formatted with power component in a different location. The section and
supply wires (2) shown across the top of the drawing component number are given in parenthesis at the
and ground wires (5) across the bottom. The bottom of the statement. In the example, power is
9015B
schematic contains no harness or connector going TO component F15 Horn Fuse, in section SE15.
05
information. 3

092005
PN=359
System Information
9015B
05
4
–UN–30OCT03
T195714

092005
PN=360
System Information
1—Component Identification 4—Wire Harness 7—Wire End #1 Termination 9—Wire Color

Number 5—Wire Number Location 10—Wire End #2 Termination
2—Connector 6—Wire Splice 8—Wire Number Location
3—Connector End View
Wiring Diagram one end of a wire. In the center, the wire number (8)
and wire color (9) are listed. A component identification
Each harness on the machine is drawn showing number in the “END #2” column (10) identifies the
connectors, wires, and splices. A “W” component opposite end of the wire.
identification number identifies harnesses. (W6, Etc.)
The harness is drawn showing spatial arrangement of Component Location Diagram
components and branches.
The Component Location Diagram is a pictorial view
A component identification or connector number (1) by harness showing location of all electrical
identifies each component. The harness branch (4) is components, connectors, harness main ground
terminated by a top or side view of the connector (2). If locations and harness band and clamp location. Each
more than one wire is supplied to the connector, a component will be identified by the same identification
harness side connector end view (3) is provided. Each letter/number and description used in the System
wire number is labeled for the appropriate pin. If only Functional Schematic Diagram.
one wire is supplied to the connector, the wire number
(5) is indicated. Connector End View Diagram—If Provided
9015B
An “X” component identification number of 100 or The Connector End View Diagram is a pictorial end
05
higher identifies splices (6). Each splice lists side A view of the component connectors showing the 5
wires and side B wires to differentiate the side of the number of pins in the connector and the wire color and
harness that the wires come from. identifier of the wire in every connector. Each
component will be identified by the same identification
A wire legend is provided for each harness. A letter/number and description used in the System
component identification number is listed in the “END Functional Schematic Diagram.
#1” column (7) to indicate the termination location of

092005
PN=361
System Information
T128823 –UN–03MAR00

092005
PN=362
9015B-05-6 - A 9015B-05-6 - B 9015B-05-6 - C
9015B-05-6 - A
T128823 –UN–03MAR00
TM2075 (03MAR05)
9015B-05-6 - B
System Information
9015B-05-6 644J and 724J Loader

092005
PN=362
9015B-05-6 - C
9015B-05-6 - Blank
System Information
1—Battery 24—Sensor 46—Resistor 62—Momentary Switch

2—Wire Splice 25—Sensor with Normally 47—Variable Resistor Normally Open
3—Fuse Open Switch 48—Multi-Pin Connector 63—Momentary Switch
4—Circuit Breaker 26—Speed Sensor 49—Single Pin Connector Normally Closed
5—Fusible Link 27—Rotary Sensor 50—Connector 64—Toggle Switch Normally
6—Power Outlet 28—Single Element Bulb 51—4 Pin Relay Open
7—Alternator 29—Dual Element Bulb 52—5 Pin Relay 65—Toggle Switch Normally
8—Air Conditioner 30—Electrically Operated 53—5 Pin Relay With Internal Closed
Compressor hydraulic Valve Suppression Diode 66—2 Way Toggle Switch
9—Compressor 31—Solenoid Normally Open 54—5 Pin Relay With Internal Normally Open
10—Liquid Pump 32—Solenoid Normally Closed Suppression Resistor 67—2 Way Toggle Switch
11—Antenna 33—Starter Motor 55—Key Switch Normally Closed
12—Diode 34—Starter Motor 56—Temperature Switch 68—Manual Switch Operation
13—Zener Diode 35—DC Motor Normally Open 69—Push Switch Operation
14—Capacitor 36—DC Stepping Motor 57—Temperature Switch 70—Pull Switch Operation
15—Magnet 37—Wiper Motor Normally Closed 71—Turn Switch Operation
16—Flasher 38—Blower Motor 58—Pressure Switch Normally 72—Toggle Switch Operation
17—Buzzer 39—Servo Motor Open 73—Pedal Switch Operation
18—Horn 40—Speedometer 59—Pressure Switch Normally 74—Key Switch Operation
19—Alarm 41—Tachometer Closed 75—Detent Switch Operation
20—Clock 42—Temperature Gauge 60—Liquid Level Switch 76—Temperature Sensor
21—Internal Ground 43—Liquid Level Gauge Normally Open 77—Solar Sensor
22—Single Point Ground 44—Gauge 61—Liquid Level Switch 78—Pressure Sensor
23—External Ground 45—Hourmeter Normally Closed 79—Liquid Level Sensor
Electrical Schematic Symbols 9015B

05
7
CED,TX17984,455 –19–07MAY01–6/6

092005
PN=363
System Information
9015B
05
8

092005
PN=364
Group 10
System Diagrams
9015B
10
1

092005
PN=365
System Diagrams
Fuse and Relay Specifications (S.N. 590068— )
9015B
10
2
–UN–12SEP03
T192491
Continued on next page MF82180,0000174 –19–08DEC03–1/2

092005
PN=366
System Diagrams
F01—Flasher 5 A Fuse F15—FLC Ignition Power 5 A F31—Spare Ignition Power 5 A F53—Alternator Excitation 5 A
F02—Brake Light Pressure Fuse Fuse Fuse
Switch 5 A Fuse F16—Spare Ignition Power 15 F32—Park Brake Release F55—Rear Wiper Motor 10 A
F03—ECU Battery Power 10 A A Fuse Switch/Back-Up Alarm 5 Fuse
Fuse F17—Spare Battery Power 15 A Fuse F56—Front Wiper Motor 10 A
F04—Converter Battery Power A Fuse F33—Pressurizer Motor 10 A Fuse
15 A Fuse F18—TCU Battery power 5 A Fuse K1—Horn Relay
F05—Blower Motor 25 A Fuse Fuse F34—CMU Battery Power 5 A V2—Start Aid Solenoid 3 A
F08—Electric Adjust Seat 10 A F19—Horn 5 A Fuse Fuse Diode
Fuse F20—Spare Battery Power 5 A F38—Differential Lock Foot V3—Ignition Relay 3 A Diode
F09—Converter Ignition Power Fuse Switch 5 A Fuse V4—Start Relay 3 A Diode
10 A Fuse F21—FLC Battery Power 10 A F40—Transmission Output V5—Alternator Excitation 3 A
F10—ECU Ignition Power 5 A Fuse Speed Sensor 5 A Fuse Diode
Fuse F23—Brake/Steering Pressure F41—Start Relay 5 A Fuse V7—Reverse Polarity 3 A
F11—Restriction Switch/Radio Switch 5 A Fuse F46—Start Aid Solenoid Diode
Ignition Power 10 A Fuse F28—TCU Ignition power 5 A Switch 5 A Fuse
F13—CMU/SSM Ignition Power Fuse F49—Radio/Diagnostic
10 A Fuse Connector/Dome Light
Battery Power 10 A Fuse
IMPORTANT: Install fuse with correct amperage • F65—Engine Heater Relay (125 A) Fuse (W7)
rating to prevent electrical system • K3—Start Relay (W3)
damage from overload. • K4—Ignition Relay (W3)
• K5—Engine Air Heater Relay (W7)
The Vehicle Electrical Center (VEC) is located in the • V1—Starter Coil Suppression 5 A Diode (W3) 9015B
load center. See Load Center Harness (W3) • V6—Engine Air Heater Relay Suppression Diode 10
Component Location (S.N. 590068— ). (Group (W7) 3
9015B-10.) • V11—A/C Compressor Clutch 1 A Diode (W6)
NOTE: The following items are located outside of the

VEC:
MF82180,0000174 –19–08DEC03–2/2

092005
PN=367
System Diagrams
System Functional Schematic, Wiring

Diagram and Component Location Legend
(S.N. 590068— )
NOTE: A2—Flex Load Controller (FLC) (SE18, SE19,

W3)
A2 indicates component identification number.
Flex Load Controller indicates component name.
SE18, SE19 indicates section numbers of system

functional schematic where component is located.
W3 is the identification number of the component

location and harness connector (with wire and pin
location) drawings for the component. This would
indicate that the Flex Load Controller is connected
to W3 Load Center Harness.
• A1—Engine Control Unit (ECU) (SE41, W3)

9015B
• A2—Flex Load Controller (FLC) (SE18, SE19, W3)
10
4 • A3—Transmission Control Unit (TCU) (SE23, W3)
• A4—Pilot Controller (SE27, W3)
• A5—12 V Radio (SE38, W34)
• A6—Sealed Switch Module (SSM) (SE39, W3)
• B1—Engine Coolant Temperature Sensor (SE40, W6)
• B3—Camshaft Position Sensor (SE41, W6)
• B4—Crankshaft Position Sensor (SE40, W6)
• B5—Fuel Temperature Sensor (SE40, W6)
• B7—Manifold Air Temperature Sensor (SE40, W6)
• B8—Hydraulic System Pressure Sensor (SE19, W5)
• B14—Analog Throttle Position Sensor (SE40, W3)
• B15—Hydraulic Oil Temperature Sensor (SE15, W5)
• B17—Fuel Level Sensor (SE15, W6)
• B19—Engine Air Filter Restriction Switch (Closed With
Restriction) (SE42, W6)
• B20—Transmission Oil Filter Restriction Switch (SE24,
W5)
• B21—Hydraulic Oil Filter Restriction Switch (SE20, W5)
• B23—Engine Oil Pressure Sensor (SE40, W6)
• B25—Steering System Pressure Switch (closes with
high pressure) (SE20, W3)
• B27—Service Brake Accumulator Charge Pressure
Switch (closes with high pressure) (SE20, W3)

092005
PN=368
System Diagrams
• B28—Torque Converter Input Speed Sensor (Engine

Speed) (SE22, W10)
• B29—Torque Converter Output Speed Sensor (SE22,
W10)
• B30—Internal Clutch Speed Sensor (SE22, W10)
• B31—Transmission Output Speed Sensor (SE22, W10)
• B32—Transmission Oil Temperature Sensor (SE32,
W18)
• B33—Clutch Cut-Off Sensor (SE24, W3)
• B34—Park Brake Pressure Switch (closes with low
pressure) (SE24, W2)
• B35—Freeze Control Switch (opens with freeze
condition) (SE32, W20)
• B38—F-Note Horn (SE33, W2)
• B40—Brake Light Pressure Switch (closes with
• B41—Ride Control Pressure Switch (closes with
• B42—Left Speaker (SE38, W34)
• B43—Right Speaker (SE38, W34)
• B45—Analog BHKO/RTC Position Sensor (SE27, W2)
• B48—Water in Fuel Sensor (SE40, W6) 9015B
• B49—Fuel Rail Pressure Sensor (SE41, W6) 10
5
• B50—A/C Binary Pressure Switch (opens with high and
low pressures) (SE32, W20)
• E2—Left Front Turn Light (SE34, W2)
• E3—Left Rear Turn Light (SE34, W13)
• E4—Right Front Turn Light (SE34, W2)
• E5—Right Rear Turn light (SE34, W13)
• E6—Left Front Marker Light (SE34, W2)
• E7—Right Front Marker Light (SE34, W2)
• E8—Left Tail Light (SE34, W13)
• E9—Right Tail Light (SE34, W13)
• E10—License Plate Light (SE34, W13)
• E11—Left Front Drive Light (SE35, W2)
• E12—Right Front Drive Light (SE35, W2)
• E15—Beacon Light (SE35, W19)
• E16—Left Rear Brake Light (SE36, W13)
• E17—Right Rear Brake Light (SE36, W13)
• E18—Dome Light (SE36, W19)
• E20—Left Front Work Light (SE37, W19)
• E21—Right Front Work Light (SE37, W19)
• E22—Left Rear Work Light (SE37, W19)
• E23—Right Rear Work Light (SE37, W19)
• E24—Left Docking Light (SE37)
• E25—Right Docking Light (SE37)

092005
PN=369
System Diagrams
• E26—Engine Air Heater (SE2, W7)

• F01—Flashers 5 A Fuse (SE4, W3)
• F02—Brake Light Pressure Switch 5 A Fuse (SE4, W3)
• F03—ECU Battery Power 10 A Fuse (SE4, W3)
• F04—Converter Battery Power 15 A Fuse (SE4, W3)
• F05—Blower Motor 25 A Fuse (SE4, W3)
• F08—Electric Adjust Seat 10 A Fuse (SE4, W3)
• F09—Converter Ignition Power 10 A Fuse (SE5, W3)
• F10—ECU Ignition Power 5 A Fuse (SE5, W3)
• F11—Restriction Switch/Radio Ignition Power 10 A
Fuse (SE5, W3)
• F13—CMU/SSM Ignition Power 5 A Fuse (SE5, W3)
• F15—FLC Ignition Power 5 A Fuse (SE5, W3)
• F16—Spare Ignition Power 15 A Fuse (SE5, W3)
• F17—Spare Battery Power 15 A Fuse (SE6, W3)
• F18—TCU Battery Power 5 A Fuse (SE6, W3)
• F19—Horn 5 A Fuse (SE6, W3)
• F20—Spare Battery Power 5 A Fuse (SE6, W3)
9015B • F21—FLC Battery Power 10 A Fuse (SE6, W3)
10 • F23—Brake/Steering Pressure Switch 5 A Fuse (SE6,
6
W3)
• F28—TCU Ignition Power 5 A Fuse (SE6, W3)
• F32—Park Brake Release Switch/Back-Up Alarm 5 A
Fuse (SE7, W3)
• F33—Pressurizer Motor 10 A Fuse (SE7, W3)
• F34—CMU Battery Power 5 A Fuse (SE7, W3)
• F38—Differential Lock Foot Switch 5 A Fuse (SE7, W3)
• F40—Transmission Output Speed Sensor 5 A Fuse
(SE8, W3)
• F41—Start Relay 5 A Fuse (SE8, W3)
• F46—Start Aid Solenoid Switch 5 A Fuse (SE8, W3)
• F49—Radio/Diagnostic/Dome Light Battery Power 10 A
Fuse (SE8, W3)
• F50—Spare Inline 5 A Fuse (SE8, W3)
• F53—Alternator Excitation 5 A Fuse (SE9, W3)
• F55—Rear Wiper Motor 10 A Fuse (SE9, W3)
• F56—Front Wiper Motor 10 A Fuse (SE9, W3)
• F65—Engine Heater Relay (125 A) Fuse (SE2, W7)
• G1—Batteries (SE1)
• G2—Emergency Starting Terminal (SE1)
• G3—24 Volt 55 Amp Alternator (SE2, W6)

092005
PN=370
System Diagrams
• G4—24 Volt 80 Amp Alternator (SE2, W6)

• G5—12 V Power Plug (SE38, W3)
• G6—24 V to 12 V Voltage Converter (SE38, W21)
• G7—24 V to 12 V Voltage Converter (Radio) (SE38,
W34)
• G8—Vehicle Electrical Center (VEC) (SE4, SE5, W3)
• G9—Power Plug (W3)
• H1—Monitor Alarm (SE14, W4)
• H2—CAN Monitor Unit (CMU) (SE14, W4)
• H3—Back-Up Alarm (SE22, W13)
• K1—Horn Relay (VEC) (SE6, W3)
• K3—Start Relay (SE3, W3)
• K4—Ignition Relay (SE3, W3)
• K5—Engine Air Heater Relay (SE2, W7)
• M1—Starter Motor (SE1, W3, W6)
• M2—Front Washer Pump (SE29, W5)
• M3—Front Wiper Motor (SE29, W4)
• M4—Rear Washer Pump (SE30, W5)
• M5—Rear Wiper Motor (SE30, W19)
• M6—Blower Motor (SE31, W20)
• M7—Pressurizer Motor (SE31, W20)
• M8—Secondary Steering Pump Motor (SE33, W17) 9015B
• M9—Air Adjust Seat Motor (SE12) 10
7
• R1—CAN Termination Node (SE13, W3)
• R2—CAN Termination Node (SE14, W4)
• R3—Blower Speed Resistor (SE31, W20)
• S1—Key Switch (SE1, W9)
• S2—Manual Battery Disconnect (SE1)
• S3—Start-Aid Switch (SE11, W4)
• S6—Automatic Transmission Switch (SSM) (SE39,
W10)
• S7—Quick Shift Switch (SE22, W3)
• S8—Park Brake Release Switch (SE22, W4)
• S9—Joystick Gear Select (SE21)
• S10—Shifter Switch (SE23)
• S11—Clutch Cut-Off Enable Switch (SSM) (SE39, W3)
• S12—Pin Disconnect Switch (SSM) (SE39, W3)
• S13—Differential Lock Foot Switch (SE28, W3)
• S17—Return-to-Dig Switch (closed while sensing metal)
(SE27, W2)
• S18—Pilot Enable Switch (SSM) (SE39, W3)
• S19—Front Wiper Switch (SSM) (SE39, W3)
• S20—Rear Wiper Switch (SSM) (SE39, W3)
• S21—Blower Speed Switch (SE31, W3)
• S22—A/C (On/Off) Switch (SSM) (SE39, W3)
• S23—Horn Switch (SE33, W4)

092005
PN=371
System Diagrams
• S24—4-way Flasher Switch (SE34, W3)

• S25—Turn Switch (SE34, W4)
• S26—Drive Light Switch (SSM) (SE39, W3)
• S27—Beacon Light Switch (SSM) (SE39, W3)
• S28—Dome Light Switch (SE36, W19)
• S29—Door Switch (opens with door closed) (SE36,
W19)
• S30—Work Light Switch (SSM) (SE39, W3)
• S31—Ride Control Switch (SSM) (SE39, W3)
• S32—Up/Down Electric Air Adjust Seat Switch (SE12)
• S33—Spin Control Switch (SSM) (SE39, W3)
• S35—Axle Disconnect Switch (SSM) (SE39, W3)
• S37—Return-to-Dig Switch (closed while sensing metal)
(forks) (tool carrier only) (SE27, W2)
• S39—Boom Height Kick Out Enable Switch (SSM)
(SE39, W3)
• S40—Return-to-Carry Enable Switch (SSM) (SE39, W3)
• S41—Reverse Fan Switch (SSM) (SE39, W3)
• S42—Return-to-Dig Enable Switch (SSM) (SE39, W3)
• S43—Front Washer Switch (SSM) (SE39, W3)
• S44—Rear Washer Switch (SSM) (SE39, W3)
9015B • V1—Starter Coil Suppression 5 A Diode (SE1, W3)
10 • V2—Start Aid Solenoid Coil 3 A Diode (VEC) (SE4, W3)
8
• V3—Ignition Relay 3 A Diode (VEC) (SE7, W3)
• V4—Start Relay 3 A Diode (VEC) (SE8, W3)
• V5—Alternator Excitation 3 A Diode (VEC) (SE9, W3)
• V6—Engine Air Heater Relay Suppression Diode (SE2,
W7)
• V11—A/C Compressor Clutch 1 A Diode (SE32, W6)
• W1—Antenna (SE39)
• W2—Loader Frame Harness
• W3—Load Center Harness
• W4—Front Console Harness
• W5—Engine Frame Harness
• W6—Engine Harness
• W7—Engine Air Heater Harness
• W9—Ride Control Harness
• W10—Transmission Harness
• W13—Rear Frame Harness
• W16—Pin Disconnect Harness (not shown)
• W17—Secondary Steering Pump Harness (not shown)
• W18—Transmission Control Valve Harness (not shown)
• W19—Cab Roof Harness
• W20—Blower/AC Harness
• W21—Converter and Power Plug Harness (not shown)
• W24—Battery Harness (4 Battery Cables)

092005
PN=372
System Diagrams
• W25—G01 Blk Ground for CMU, TCU, CCU at Starter

• W26—G02 Blk Ground for Engine Frame Components
by Starter
• W27—G03 Blk Ground for Engine Components at
Starter
• W28—G04 Blk Ground for Cab Components in Load
Center
• W29—G05 Blk Ground for Loader Frame Components
at Right Front Cab Leg
• W30—G08 Blk Ground for Front Dash Components in
Load Center
• W31—G09 Blk Ground for Engine Air Heaters
• W33—Axle Disconnect Harness (not shown)
• W34—Radio Harness
• X1—Service ADVISOR System Connector (SE13, W3)
• X2—TCU Diagnostic and Programming Connector
(SE24, W3)
• X3—Load Center Harness-to-Engine Frame Harness
Connector (W3, W5)
• X4—Load Center Harness-to-Engine Harness
Connector (W3, W6)
• X5—Load Center Harness-to-Cab Roof Harness (8-pin) 9015B
Connector (W3, W19) 10
9
• X6—Load Center Harness-to-Cab Roof Harness (6-pin)
Connector (W3, W19)
• X7—Load Center Harness-to-Blower and A/C Harness
(3-pin) Connector (W3, W20)
• X10—Vehicle Electrical Center (8-Pin) Black Connector
(W3)
• X11—Vehicle Electrical Center (8-Pin) Gray Connector
(W3)
• X12—Vehicle Electrical Center (8-Pin) Blue Connector
(W3)
• X13—Vehicle Electrical Center (8-Pin) Green Connector
(W3)
• X14—Vehicle Electrical Center (2-Pin) Gray Connector
(W3)
• X15—Vehicle Electrical Center (2-Pin) Black Connector
(W3)
• X16—Vehicle Electrical Center (8-Pin) Orange
Connector (W3)

092005
PN=373
System Diagrams
• X17—Vehicle Electrical Center (8-Pin) Yellow

Connector (W3)
• X18—Vehicle Electrical Center (8-Pin) Red Connector
(W3)
• X19—Load Center Harness Spare BAT Connector (W3)
• X20—Load Center Harness Spare IGN Connector (W3)
• X21—Load Center Harness Spare GND Connector
(W3)
• X22—Load Center Harness-to-Transmission Harness
Connector (W3, W10)
• X23—Transmission Control Unit (TCU) Connector (W3)
• X24—Engine Control Unit (ECU) Connector (W3)
• X25—Engine Control Unit (ECU) Connector (W3)
• X26—Shifter Switch Connector 1 (W3)
• X27—Joystick Gear Select Connector 1 (W3)
• X28—Shifter Switch Connector 2 (W3)
• X29—Joystick Gear Select Connector 2 (W3)
• X30—Load Center Harness-to-Front Console Harness
Connector (W3, W4)
• X31—Load Center Harness-to-Loader Frame Harness
Connector 1 (W3, W2)
9015B • X32—Load Center Harness-to-Loader Frame Harness
10 Connector 2 (W3, W2)
10
• X33—Load Center Harness-to-Air Adjust Seat Harness
Connector (W3)
• X34—Load Center Harness-to-Radio Harness
Connector (W3)
• X35—Load Center Harness-to-Converter and Power
Plug Harness Connector (W3, W21)
• X36—Transmission Harness-to-Transmission Control
Valve Harness Connector (W10, W18)
• X37—Engine Harness-to-Secondary Steering Pump
Motor Harness Connector (W6, W17)
• X38—Engine Harness-to-Engine Air Heater Harness
Connector (W6, W7)
• X39—Engine Frame Harness-to-Rear Frame Harness
Connector (W5, W13)
• X40—Flex Load Controller Connector (J1) (Brn) (W3)
• X41—Flex Load Controller Connector (J2) (Brn) (W3)
• X42—Flex Load Controller Connector (J3) (Blu) (W3)
• X43—12 Volt Center Tap Battery Connector (W5)
• X44—Loader Frame Harness-to-Ride Control Harness
Connector (W2, W9)
• X45—Loader Frame Harness-to-Pin Disconnect
Harness Connector (W2, W16)

092005
PN=374
System Diagrams
• X46—Loader Frame Harness-to-Axle Disconnect

• X48—CAN Monitor Unit Connector (W4)
• X49—Engine Harness-to-Electronic Injector (EI)
• X50—Shifter Switch (W4)
• X51—Shifter Switch (W4)
• X52—A/C Pressure Switch Jumpered Connector (W20)
• X53—Sealed Switch Module Connector (W3)
• X100—W2 Splice S1 (W2)
• X112—W3 Splice S32 (W3) 9015B
• X113—W3 Splice S30 (W3) 10
11

092005
PN=375
System Diagrams

• X152—W10 Splice S1 (W10)
• X153—W13 Splice S2 (W13)
• X154—W13 Splice S3 (W13)
• X155—W13 Splice S1 (W13)
• X157—W19 Splice S1 (W19)
• X158—W19 Splice S2 (W19)
• X159—W19 Splice S3 (W19)
• X160—W19 Splice S4 (W19)
9015B • X161—W20 Splice S1 (W20)
10 • X162—W6 Splice S4 (W6)
12
• X163—W4 Spice S4 (W4)
• X165—W34 Splice S1 (W34)
• Y1—Transmission Control Solenoid 1 (SE23, W18)
• Y7—Start Aid Solenoid (SE11, W5)
• Y8—High Pressure Fuel Pump Solenoid (SE42, W6)
• Y9—High Pressure Fuel Pump Solenoid (SE42, W6)
• Y13—Differential Lock Solenoid (SE28, W5)
• Y14—Pilot Enable Solenoid (SE25, W5)
• Y15—Boom Down Accumulator Solenoid (SE25, W5)

092005
PN=376
System Diagrams
• Y17—Ride Control Boom Solenoid (SE10, W9)

• Y16—A/C Compressor Clutch (SE32, W6)
• Y18—Ride Control (On/Off) Solenoid (SE10, W9)
• Y19—Park Brake Release Solenoid (SE24, W2)
• Y20—Pin Disconnect Solenoid (SE28, W16)
• Y21—Electronic Injector (EI) 1 (SE42, W35)
• Y28—Axle Disconnect Solenoid (SE28, W33)
• Y34—Ride Control (On/Off) Solenoid (SE10, W9)
• Y37—Proportional Fan Solenoid (SE18, W5)
• Y38—Reverse Fan Solenoid (SE17, W5)
TX14826,0000068 –19–15AUG03–10/10
9015B
10
13

092005
PN=377
System Diagrams
System Functional Schematic and Section Legend (S.N. 590068— )
9015B
10
14
–19–01MAR05
T208315
System Functional Schematic (1 of 2) (SE1 - SE24)
Continued on next page TX14826,000006A –19–01MAR05–1/4

092005
PN=378
9015B-10-14 - A 9015B-10-14 - B 9015B-10-14 - C 9015B-10-14 - D 9015B-10-14 - E 9015B-10-14 - F 9015B-10-14 - G 9015B-10-14 - H 9015B-10-14 - I 9015B-10-14 - J 9015B-10-14 - K 9015B-10-14 - L 9015B-10-14 - M 9015B-10-14 - N 9015B-10-14 - O 9015B-10-14 - P 9015B-10-14 - Q 9015B-10-14 - R 9015B-10-14 - S 9015B-10-14 - T 9015B-10-14 - U
System Diagrams
System Functional Schematic and Section Legend (S.N. 590068— )
9015B
10
14


092005
PN=378
9015B-10-14 - A
9015B-10-14 - B
9015B-10-14 - C
T208315 –19–01MAR05
T208315 –19–01MAR05
9015B-10-14 - D
9015B-10-14 - E
9015B-10-14 - F
9015B-10-14 - G
9015B-10-14 - H
9015B-10-14 - I
9015B-10-14 - J
9015B-10-14 - K
9015B-10-14 - L
9015B-10-14 - M
9015B-10-14 - N
9015B-10-14 - O
9015B-10-14 - P
9015B-10-14 - Q
9015B-10-14 - R
9015B-10-14 - S
9015B-10-14 - T
9015B-10-14 - U
9015B-10-14 - V
System Diagrams
NOTE: SE1—Battery, Ignition Power Circuit (24 V Battery, Ignition Power Circuit (24 V System)
System) indicates circuit name.
SE1 indicates section number of System

Functional Schematic where circuit is located.
9015B
10
15

092005
PN=379
System Diagrams
9015B
10
16
–19–21DEC04
T204678
• SE1—Battery, Ignition Power Circuit (24 V System) • SE2—Alternator and Engine Air Heater Circuits

092005
PN=380
9015B-10-16 - A 9015B-10-16 - B 9015B-10-16 - C 9015B-10-16 - D 9015B-10-16 - E 9015B-10-16 - F 9015B-10-16 - G 9015B-10-16 - H 9015B-10-16 - I 9015B-10-16 - J 9015B-10-16 - K 9015B-10-16 - L 9015B-10-16 - M 9015B-10-16 - N 9015B-10-16 - O 9015B-10-16 - P
System Diagrams
9015B
10
16
• SE1—Battery, Ignition Power Circuit (24 V System) • SE2—Alternator and Engine Air Heater Circuits

092005
PN=380
9015B-10-16 - A
9015B-10-16 - B
9015B-10-16 - C
T204678 –19–21DEC04
9015B-10-16 - D
9015B-10-16 - E
9015B-10-16 - F
9015B-10-16 - G
9015B-10-16 - H
9015B-10-16 - I
9015B-10-16 - J
9015B-10-16 - K
9015B-10-16 - L
9015B-10-16 - M
9015B-10-16 - N
9015B-10-16 - O
9015B-10-16 - P
System Diagrams
• SE3—Starting Circuit • SE24—Transmission Control Unit (TCU) Circuit

• SE4—Vehicle Electrical Center (VEC) Circuit • SE25—Pilot Enable and Boom Down Circuit
• SE5—Vehicle Electrical Center (VEC) Circuit • SE26—Return-to-Dig Circuit
• SE6—Vehicle Electrical Center (VEC) Circuit • SE27—Boom Height Kickout and Return-to-Dig
• SE7—Vehicle Electrical Center (VEC) Circuit Circuit
• SE8—Vehicle Electrical Center (VEC) Circuit • SE28—Differential Lock, Pin Disconnect and Axle
• SE9—Vehicle Electrical Center (VEC) Circuit Disconnect Circuit
• SE10—Ride Control Circuit • SE29—Front Wiper Circuit
• SE11—Start Aid and Horn Circuit • SE30—Rear Wiper Circuit
• SE12—Electric Adjust Seat Circuit • SE31—Heater/Pressurizer Circuit
• SE13—CAN Monitor Unit (CMU) Circuit • SE32—Air Conditioning Circuit
• SE14—CAN Monitor Unit (CMU) Circuit • SE33—Flasher and Turn Signal Circuit
• SE15—CAN Monitor Unit (CMU) Circuit • SE34—Tail/Marker Light Circuit
• SE16—Flex Load Controller (FLC) Circuit • SE35—Drive Light and Beacon Light Circuit
• SE17—Flex Load Controller (FLC) Circuit • SE36—Brake Light and Dome Light Circuit
• SE18—Flex Load Controller (FLC) Circuit • SE37—Cab Work Light Circuit
• SE19—Flex Load Controller (FLC) Circuit • SE38—Converter and Radio Circuits
• SE20—Flex Load Controller (FLC) Circuit • SE39—Sealed Switch Module (SSM) Circuit
• SE21—Column FNR/Gear Select Circuit (Option) • SE40—Engine Control Unit (ECU) Input Circuit
• SE22—Transmission Control Unit (TCU) Circuit • SE41—Engine Control Unit (ECU) Circuit
• SE23—Transmission Control Unit (TCU) Circuit • SE42—Engine Control Unit (ECU) Output Circuit
9015B
10
17
TX14826,000006A –19–01MAR05–4/4

092005
PN=381
System Diagrams
Loader Frame Harness (W2) Component Location (S.N. 590068— )
E4
E7
E2
E6 X31
X32
B38
E11
S17
E12
B45
9015B
10
18 W2
X44 –UN–13OCT03
B34
X45
X46
T191948
Y19
T191948
Loader Frame Harness (W2) Harness Component Location
Continued on next page TX14826,000006B –19–23JUN03–1/2

092005
PN=382
System Diagrams
B34—Park Brake Pressure E7—Right Front Marker Light X44—Loader Frame X46—Loader Frame
Switch (closes with low E11—Left Front Drive Light Harness-to-Ride Control Harness-to-Axle
pressure) E12—Right Front Drive Light Harness Connector Disconnect Harness
B38—F-Note Horn S17—Return-to-Dig Switch X45—Loader Frame Connector
B45—Analog BHKO/RTC X31—Load Center Harness-to-Pin Y19—Park Brake Release
Position Sensor Harness-to-Loader Disconnect Harness Solenoid
E2—Left Front Turn Light Frame Harness Connector
E4—Right Front Turn Light Connector 1
E6—Left Front Marker Light X32—Load Center
Harness-to-Loader
Frame Harness
Connector 2
TX14826,000006B –19–23JUN03–2/2
9015B
10
19

092005
PN=383
System Diagrams
Loader Frame Harness (W2) Wiring Diagram (S.N. 590068— )

T191967 –UN–06OCT03
Loader Frame Harness (W2) Wiring Diagram

TX14826,000006C –19–23JUN03–1/2

092005
PN=384
9015B-10-20 - A 9015B-10-20 - B
Loader F
T191967 –UN–0
TM2075 (03
9015B-10-20 - A
System Diagrams
der Frame Harness (W2) Wiring Diagram (S.N. 590068— )

–UN–06OCT03
Loader Frame Harness (W2) Wiring Diagram

TX14826,000006C –19–23JUN03–1/2
5 (03MAR05) 9015B-10-20 644J and 724J Loader

092005
PN=384
9015B-10-20 - B
System Diagrams
B34—Park Brake Pressure E11—Left Front Drive Light X44—Loader Frame X100—W2 Splice S1
Switch (closes with low E12—Right Front Drive Light Harness-to-Ride Control X102—W2 Splice S4
pressure) S17—Return-to-Dig Switch Harness Connector X103—W2 Splice S5
B38—F-Note Horn X31—Load Center X45—Loader Frame Y19—Park Brake Release
B45—Analog BHKO/RTC Harness-to-Loader Harness-to-Pin Solenoid
Position Sensor Frame Harness Disconnect Harness
E2—Left Front Turn Light Connector 1 Connector
E4—Right Front Turn Light X32—Load Center X46—Loader Frame
E6—Left Front Marker Light Harness-to-Loader Harness-to-Axle
E7—Right Front Marker Light Frame Harness Disconnect Harness
Connector 2 Connector
TX14826,000006C –19–23JUN03–2/2
9015B
10
21

092005
PN=385
System Diagrams
Load Center Harness (W3) Component Location (S.N. 590068— )

T191950 –UN–10DEC03
X1
S21
S21 S1 S1 A4 A6 X53
A6 A6 S24
S24
G8
A1
A4
X11
G9 X15 X10
X14 X18
G5
G5 X17
X1 A2 X1 X25
W25
X24 X16
B27 B40
X29
X16 X13
X2 A3
M1 B25
X40 X12
X27 X41
W28 G9
W29 A2
W30 V1 X42 X33
X8
X8 X7
B14
B40 X7 X9
K3 X22
R1 K4 X9
X33
X30 X23 X3
B27 X4
B25
S13 B33
X34 X21
X31 X32
X20 X19 X5
X6
X35
T191950
Load Center Harness (W3) Component Location
TX14826,000006D –19–23JUN03–1/2

092005
PN=386
9015B-10-22 - A 9015B-10-22 - B 9015B-10-22 - C
S21 S1
A6
S24
G8
A1
G9
X1 A2 X1
W25
X2 A3
M1
W28
W29
W30 V1
B14
B40
X30
B27
B25
S13 B33
X31 X32
T191950
9015B-10-22 - A
Load Center Harne
T191950 –UN–10DEC03
S21
A6 S1
S24
A4
X11
X15 X10
X14 X18
G5 X17
X25
X24 X16
X29
B25
X40
X27 X41
G
X42
X8
X7 X9
K3
R1 X33 K4
X23
TM2075 (03MAR05)
9015B-10-22 - B
System Diagrams
arness (W3) Component Location (S.N. 590068— )
X1
A4 A6 X53
G5
B27 B40
X16 X13
25
X12
G9
A2
X33
X8
X7
X9 X22
X3
X4
X34 X21
X20 X19 X5
X6
X35
Load Center Harness (W3) Component Location

TX14826,000006D –19–23JUN03–1/2
9015B-10-22 644J and 724J Loader

092005
PN=386
9015B-10-22 - C
9015B-10-22 - Blank
System Diagrams
A1—Engine Control Unit (ECU) W28—G04 Blk Ground for Cab X9—Load Center X27—Joystick Gear Select
A2—Flex Load Controller Components in Load Harness-to-Blower and Connector 1
(FLC) Center A/C Harness (4-pin) X29—Joystick Gear Select
A3—Transmission Control Unit W29—G05 Blk Ground for Connector Connector 2
(TCU) Loader Frame X10—Vehicle Electrical Center X30—Load Center Harness to
A4—Pilot Controller Components at Right 8-Pin Black Connector Front Console Harness
A6—Sealed Switch Module Front Cab Leg X11—Vehicle Electrical Center Connector
(SSM) W30—G08 Blk Ground for 8-Pin Gray Connector X31—Load Center
B14—Analog Throttle Position Front Dash Components X12—Vehicle Electrical Center Harness-to-Loader
Sensor in Load Center 8-Pin Blue Connector Frame Harness
B25—Steering System X1—Service ADVISOR System X13—Vehicle Electrical Center Connector 1
Pressure Switch (closes Connector 8-Pin Green Connector X32—Load Center
with high pressure) X2—TCU Diagnostic and X14—Vehicle Electrical Center Harness-to-Loader
B33—Clutch Cut-Off Sensor Programming Connector 2-Pin Gray Connector Frame Harness
B40—Brake Light Pressure X3—Load Center X15—Vehicle Electrical Center Connector 2
Switch (closes with Harness-to-Engine Frame 2-Pin Black Connector X33—Load Center
pressure) Harness Connector X16—Vehicle Electrical Center Harness-to-Air Adjust
G5—Power Plug X4—Load Center 8-Pin Orange Connector Seat Harness Connector
G8—Vehicle Electrical Center Harness-to-Engine X17—Vehicle Electrical Center X34—Load Center
(VEC) Harness Connector 8-Pin Yellow Connector Harness-to-Radio
G9—Power Plug X5—Load Center X18—Vehicle Electrical Center Harness Connector
K3—Start Relay Harness-to-Cab Roof 8-Pin Red Connector X35—Load Center
K4—Ignition Relay Harness (8-pin) Connector X19—Load Center Harness Harness-to-Converter
M1—Starter Motor X6—Load Center Spare BAT Connector and Power Plug Harness
R1—CAN Termination Node Harness-to-Cab Roof X20—Load Center Harness Connector
S1—Key Switch (SE1, W3) Harness (6-pin) Connector Spare IGN Connector X40—Flex Load Controller 9015B
S13—Differential Lock Foot X7—Load Center X21—Load Center Harness Connector (J2) (Brn) 10
Switch Harness-to-Blower and Spare GND Connector X41—Flex Load Controller 23
S21—Blower Speed Switch A/C Harness (3-pin) X22—Load Center Connector (J2) (Brn)
S24—4-way Flasher Switch Connector Harness-to-Transmission X42—Flex Load Controller
V1—Starter Coil Suppression 5 X8—Load Center Harness Connector Connector (J3) (Blu)
A Diode Harness-to-Blower and X23—Transmission Control X53—Sealed Switch Module
W25—G01 Blk Ground for A/C Harness (2-pin) Unit (TCU) Connector Connector (W3)
CMU, TCU, CCU at Connector X24—Engine Control Unit
Starter (ECU) Connector
TX14826,000006D –19–23JUN03–2/2

092005
PN=387
System Diagrams
Load Center Harness (W3) Wiring Diagram (S.N. 590068— )

T191968 –UN–06OCT03
TX14826,000006E –19–05NOV04–1/13

092005
PN=388
9015B-10-24 - A 9015B-10-24 - B 9015B-10-24 - C
9015B-10-24 - A
Load Center Harne
T191968 –UN–06OCT03
TM2075 (03MAR05)
9015B-10-24 - B
System Diagrams
arness (W3) Wiring Diagram (S.N. 590068— )
TX14826,000006E –19–05NOV04–1/13
9015B-10-24 644J and 724J Loader

092005
PN=388
9015B-10-24 - C
9015B-10-24 - Blank
System Diagrams
9015B
10
25

092005
PN=389
System Diagrams
T195289 –UN–06OCT03
Load Center Harness (W3) Wiring Diagram (Main Harness)
TX14826,000006E –19–05NOV04–2/13

092005
PN=390
9015B-10-26 - A 9015B-10-26 - B 9015B-10-26 - C
9015B-10-26 - A
T195289 –UN–06OCT03
TM2075 (03MAR05)
9015B-10-26 - B
System Diagrams
Load Center Harness (W3) Wiring Diagram (Main Harness)
TX14826,000006E –19–05NOV04–2/13
9015B-10-26 644J and 724J Loader

092005
PN=390
9015B-10-26 - C
9015B-10-26 - Blank
System Diagrams
K4—Ignition Relay X6—Load Center X9—Load Center X21—Load Center Harness

X2—TCU Diagnostic and Harness-to-Cab Roof Harness-to-Blower and Spare GND Connector
Programming Connector Harness (6-pin) Connector A/C Harness (4-pin) X35—Load Center
X3—Load Center X7—Load Center Connector Harness-to-Converter
Harness-to-Engine Frame Harness-to-Blower and X19—Load Center Harness and Power Plug Harness
Harness Connector A/C Harness (3-pin) Spare BAT Connector Connector
X4—Load Center Connector X20—Load Center Harness X109—W3 Splice S6
Harness-to-Engine X8—Load Center Spare IGN Connector X114—W3 Splice S28
Harness Connector Harness-to-Blower and
X5—Load Center A/C Harness (2-pin)
Harness-to-Cab Roof Connector
Harness (8-pin) Connector
Continued on next page TX14826,000006E –19–05NOV04–3/13
9015B
10
27

092005
PN=391
System Diagrams
T204681 –UN–21DEC04
Load Center Harness (W3) Wiring Diagram (Detail #1)

092005
PN=392
9015B-10-28 - A 9015B-10-28 - B 9015B-10-28 - C
9015B-10-28 - A
T204681 –UN–21DEC04
TM2075 (03MAR05)
9015B-10-28 - B
System Diagrams
9015B-10-28 644J and 724J Loader

092005
PN=392
9015B-10-28 - C
9015B-10-28 - Blank
System Diagrams
G5—12 V Power Plug X12—Vehicle Electrical Center X17—Vehicle Electrical Center X105—W3 Splice S10
G9—Power Plug 8-Pin Blue Connector 8-Pin Yellow Connector X106—W3 Splice S4
S1—Key Switch (SE1, W3) X13—Vehicle Electrical Center X18—Vehicle Electrical Center X108—W3 Splice S1
S21—Blower Speed Switch 8-Pin Green Connector 8-Pin Red Connector X121—W3 Splice S9
S24—4-way Flasher Switch X14—Vehicle Electrical Center X34—Load Center X128—W3 Splice S24
X10—Vehicle Electrical Center 2-Pin Gray Connector Harness-to-Radio X133—W3 Splice S12
8-Pin Black Connector X15—Vehicle Electrical Center Harness Connector X170—W3 Splice S39
X11—Vehicle Electrical Center 2-Pin Black Connector X104—W3 Splice S14
8-Pin Gray Connector X16—Vehicle Electrical Center
8-Pin Orange Connector
9015B
10
29

092005
PN=393
System Diagrams
T195291 –UN–06OCT03

092005
PN=394
9015B-10-30 - A 9015B-10-30 - B
T195291 –UN–0
TM2075 (03
9015B-10-30 - A
System Diagrams
–UN–06OCT03

092005
PN=394
9015B-10-30 - B
System Diagrams
X40—Flex Load Controller X42—Flex Load Controller X110—W3 Splice S34 X112—W3 Splice S32
Connector (J2) (Brn) Connector (J3) (Blu) X111—W3 Splice S33 X113—W3 Splice S30
X41—Flex Load Controller X107—W3 Splice S31
Connector (J2) (Brn)
9015B
10
31

092005
PN=395
System Diagrams
T195292 –UN–06OCT03

092005
PN=396
9015B-10-32 - A 9015B-10-32 - B
T195292 –UN–0
TM2075 (03
9015B-10-32 - A
System Diagrams
–UN–06OCT03

092005
PN=396
9015B-10-32 - B
System Diagrams
K3—Start Relay X33—Load Center X122—W3 Splice S19 X124—W3 Splice S2

K4—Ignition Relay Harness-to-Air Adjust X123—W3 Splice S21 X171—W3 Splice S5
X23—Transmission Control Seat Harness Connector
Unit (TCU) Connector
9015B
10
33

092005
PN=397
System Diagrams
T204677 –UN–21DEC04

092005
PN=398
9015B-10-34 - A 9015B-10-34 - B
T204677 –UN–2
TM2075 (03
9015B-10-34 - A
System Diagrams
–UN–21DEC04

092005
PN=398
9015B-10-34 - B
System Diagrams
A4—Pilot Controller X24—Engine Control Unit X53—Sealed Switch Module X119—W3 Splice S13
R1—CAN Termination Node (ECU) Connector Connector (W3) X125—W3 Splice S18
X1—Service ADVISOR System X25—Engine Control Unit X115—W3 Splice S7 X167—W3 Splice S36
Connector (ECU) Connector X116—W3 Splice S8 X168—W3 Splice S35
X22—Load Center X27—Joystick Gear Select X117—W3 Splice S22 X169—W3 Splice S38
Harness-to-Transmission Connector 1 X118—W3 Splice S3
Harness Connector X29—Joystick Gear Select
Connector 2
9015B
10
35

092005
PN=399
System Diagrams
T195294 –UN–06OCT03

092005
PN=400
9015B-10-36 - A 9015B-10-36 - B 9015B-10-36 - C
9015B-10-36 - A
T195294 –UN–06OCT03
TM2075 (03MAR05)
9015B-10-36 - B
System Diagrams
9015B-10-36 644J and 724J Loader

092005
PN=400
9015B-10-36 - C
9015B-10-36 - Blank
System Diagrams
B14—Analog Throttle Position M1—Starter Motor W30—G08 Blk Ground for X126—W3 Splice S29
Sensor S13—Differential Lock Foot Front Dash Components X127—W3 Splice S28
B25—Steering System Switch in Load Center X129—W3 Splice S17
Pressure Switch (closes V1—Starter Coil Suppression 5 X30—Load Center Harness to X130—W3 Splice S25
with high pressure) A Diode Front Console Harness X131—W3 Splice S20
B27—Service Brake W25—G01 Blk Ground for Connector X132—W3 Splice S11
Accumulator Charge CMU, TCU, CCU at X31—Load Center X134—W3 Splice S15
Pressure Switch (closes Starter Harness-to-Loader X135—W3 Splice S16
with high pressure) W28—G04 Blk Ground for Cab Frame Harness X136—W3 Splice S23
B33—Clutch Cut-Off Sensor Components in Load Connector 1
B40—Brake Light Pressure Center X32—Load Center
Switch (closes with W29—G05 Blk Ground for Harness-to-Loader
pressure) Loader Frame Frame Harness
Components at Right Connector 2
Front Cab Leg
TX14826,000006E –19–05NOV04–13/13
9015B
10
37

092005
PN=401
System Diagrams
Front Console Harness (W4) Component Location (S.N. 590068— )
H2
X48
R2
9015B
10
H1
38
S8
S23
M3
S25
S3 X50
X51
–UN–13OCT03
X30
T191951
T191951
Front Console Harness (W4) Component Location
Continued on next page TX14826,0000074 –19–24JUN03–1/2

092005
PN=402
System Diagrams
H1—Monitor Alarm S8—Park Brake Release X30—Load Center X48—CAN Monitor Unit
H2—CAN Monitor Unit (CMU) Switch Harness-to-Front Connector (CMU)
M3—Front Wiper Motor S23—Horn Switch Console Harness X50—Shifter Switch
R2—CAN Termination Node S25—Turn Switch Connector X51—Shifter Switch
S3—Start-Aid Switch
TX14826,0000074 –19–24JUN03–2/2
9015B
10
39

092005
PN=403
System Diagrams
Front Console Harness (W4) Wiring Diagram (S.N. 590068— )

T191970 –UN–06OCT03
Front Console Harness (W4) Wiring Diagram

TX14826,0000071 –19–24JUN03–1/2

092005
PN=404
9015B-10-40 - A 9015B-10-40 - B
Front Co
T191970 –UN–0
TM2075 (03
9015B-10-40 - A
System Diagrams
t Console Harness (W4) Wiring Diagram (S.N. 590068— )

–UN–06OCT03
Front Console Harness (W4) Wiring Diagram

TX14826,0000071 –19–24JUN03–1/2

092005
PN=404
9015B-10-40 - B
System Diagrams
H1—Monitor Alarm S23—Horn Switch X48—CAN Monitor Unit X138—W4 Splice S2

M3—Front Wiper Motor S25—Turn Switch Connector X139—W4 Splice S3
R2—CAN Termination Node X30—Load Center X50—Shifter Switch X163—W4 Splice S5
S3—Start-Aid Switch Harness-to-Front X51—Shifter Switch X164—W4 Splice S4
S8—Park Brake Release Console Harness X137—W4 Splice S1
Switch Connector
TX14826,0000071 –19–24JUN03–2/2
9015B
10
41

092005
PN=405
System Diagrams
Engine Frame Harness (W5) Component Location (S.N. 590068— )

T195474 –UN–10DEC03
X3
B15
B21
Y7
B8 Y13
Y14 W26 M2
M4
Y15
X39
X43
Y38
Y37
T195474
Engine Frame Harness (W5) Component Location
TX14826,0000075 –19–24JUN03–1/2

092005
PN=406
9015B-10-42 - A 9015B-10-42 - B
Engine F
T195474 –UN–1
X3
B15
B21
B8 Y13
Y14 W26 M2
M4
Y15
T195474
TM2075 (03
9015B-10-42 - A
System Diagrams
ne Frame Harness (W5) Component Location (S.N. 590068— )

–UN–10DEC03
Y7
M4
X39
X43
Y38
Y37
Engine Frame Harness (W5) Component Location

TX14826,0000075 –19–24JUN03–1/2

092005
PN=406
9015B-10-42 - B
System Diagrams
B8—Hydraulic System M4—Rear Washer Pump X39—Engine Frame Y14—Pilot Enable Solenoid
Pressure Sensor W26—G02 Blk Ground for Harness-to-Rear Frame Y15—Boom Down
B15—Hydraulic Oil Engine Frame Harness Connector Accumulator Solenoid
Temperature Sensor Components by Starter X43—12 Volt Center Tap Y37—Variable Speed Fan
B21—Hydraulic Oil Filter X3—Load Center Battery Connector Motor Relief Solenoid
Restriction Switch Harness-to-Engine Frame Y7—Start Aid Solenoid Y38—Reverse Fan Solenoid
M2—Front Washer Pump Harness Connector Y13—Differential Lock
Solenoid
TX14826,0000075 –19–24JUN03–2/2
9015B
10
43

092005
PN=407
System Diagrams
Engine Frame Harness (W5) Wiring Diagram (S.N. 590068— )

T195476 –UN–29OCT03
Engine Frame Harness (W5) Wiring Diagram

TX14826,0000072 –19–24JUN03–1/2

092005
PN=408
9015B-10-44 - A 9015B-10-44 - B 9015B-10-44 - C
9015B-10-44 - A
Engine Frame Har
T195476 –UN–29OCT03
TM2075 (03MAR05)
9015B-10-44 - B
System Diagrams
Harness (W5) Wiring Diagram (S.N. 590068— )
Engine Frame Harness (W5) Wiring Diagram

TX14826,0000072 –19–24JUN03–1/2
9015B-10-44 644J and 724J Loader

092005
PN=408
9015B-10-44 - C
9015B-10-44 - Blank
System Diagrams
B8—Hydraulic System W26—G02 Blk Ground for X43—12 Volt Center Tap Y14—Pilot Enable Solenoid
Pressure Sensor Engine Frame Battery Connector Y15—Boom Down
B15—Hydraulic Oil Components by Starter X140—W5 Splice S1 Accumulator Solenoid
Temperature Sensor X3—Load Center X141—W5 Splice S2 Y37—Variable Speed Fan
B21—Hydraulic Oil Filter Harness-to-Engine Frame X142—W5 Splice S3 Motor Relief Solenoid
Restriction Switch Harness Connector Y7—Start Aid Solenoid Y38—Reverse Fan Solenoid
M4—Rear Washer Pump X39—Engine Frame Y13—Differential Lock
M2—Front Washer Pump Harness-to-Rear Frame Solenoid
Harness Connector
TX14826,0000072 –19–24JUN03–2/2
9015B
10
45

092005
PN=409
System Diagrams
Engine Harness (W6) Component Location (S.N. 590068— )
X4
X49
9015B B19
10 B49
46 Y9
B5 Y8
B23
B1
B4
B3
B48
–UN–05DEC03
T195477
B17 G3/G4
T195477
Engine Harness (W6) Component Location (1 of 2)

092005
PN=410
System Diagrams
B1—Engine Coolant B23—Engine Oil Pressure X38—Engine Y8—High Pressure Fuel Pump
Temperature Sensor Sensor Harness-to-Engine Air Solenoid
B3—Camshaft Position Sensor B48—Water in Fuel Sensor Heater Harness Y9—High Pressure Fuel Pump
B4—Crankshaft Position B49—Fuel Rail Pressure Connector Solenoid
Sensor Sensor X49—Engine
B5—Fuel Temperature Sensor G3—24 Volt 55 Amp Alternator Harness-to-Electronic
B17—Fuel Level Sensor G4—24 Volt 80 Amp Alternator Injector (EI) Harness
B19—Engine Air Filter X4—Load Center Connector
Restriction Switch Harness-to-Engine
Harness Connector
9015B
10
47

092005
PN=411
System Diagrams
9015B
10
48
B7
X37
X4
Y16
V11
–UN–08DEC03
M1 X38
W27
T195478
T195478
Engine Harness (W6) Component Location (2 of 2)

092005
PN=412
System Diagrams
B7—Manifold Air Temperature X4—Load Center X38—Engine Y16—A/C Compressor Clutch

Sensor Harness-to-Engine Harness-to-Engine Air
M1—Starter Motor Harness Connector Heater Harness
V11—A/C Clutch Diode X37—Engine Connector
W27—Ground for Engine Harness-to-Secondary
Components at Starter Steering Pump Motor
Harness Connector
TX14826,0000073 –19–24JUN03–4/4
9015B
10
49

092005
PN=413
System Diagrams
Engine Harness (W6) Wiring Diagram (S.N. 590068— )

T195479 –UN–25NOV03
Engine Harness (W6) Wiring Diagram

TX14826,0000076 –19–24JUN03–1/2

092005
PN=414
9015B-10-50 - A 9015B-10-50 - B 9015B-10-50 - C
9015B-10-50 - A
Engine Harness (W
T195479 –UN–25NOV03
TM2075 (03MAR05)
9015B-10-50 - B
System Diagrams
ss (W6) Wiring Diagram (S.N. 590068— )
Engine Harness (W6) Wiring Diagram

TX14826,0000076 –19–24JUN03–1/2
9015B-10-50 644J and 724J Loader

092005
PN=414
9015B-10-50 - C
9015B-10-50 - Blank
System Diagrams
B1—Engine Coolant B48—Water and Fuel Sensor X37—Engine X143—W6 Splice S3

Temperature Sensor B49—Fuel Rail Pressure Harness-to-Secondary X144—W6 Splice S2
B3—Camshaft Position Sensor Sensor Steering Pump Motor X147—W6 Splice S1
B4—Crankshaft Position G3—24 Volt 55 Amp Alternator Harness X148—W6 Splice S2
Sensor G4—24 Volt 80 Amp Alternator X38—Engine X149—W6 Splice S3
B7—Manifold Air Temperature M1—Starter Motor Harness-to-Engine Air X162—W6 Splice S4
Sensor V11—A/C Clutch Diode Heater Harness Y16—A/C Compressor Clutch
B17—Fuel Level Sensor W27—G03 Blk Ground for Connector Y35—Injection Pump Solenoid
B19—Engine Air Filter Engine Components at X49—Engine Y36—Injection Pump Solenoid
Restriction Switch Starter Harness-to-Electronic
(closed with restriction) X4—Load Center Injector (EI) Harness
B23—Engine Oil Pressure Harness-to-Engine Connector
Sensor Harness Connector
TX14826,0000076 –19–24JUN03–2/2
9015B
10
51

092005
PN=415
System Diagrams
Engine Air Heater Harness (W7) Component Location (S.N. 590068— )
V6
K5
F65
9015B
10
52 E26
E27
E28
X38
M1
M1
–UN–07JAN04
T196864
T196864
Engine Air Heater Harness (W7) Component Location
Continued on next page TX14826,000007A –19–24JUN03–1/2

092005
PN=416
System Diagrams
E26—Engine Air Heater K5—Engine Air Heater Relay V6—Engine Air Heater Relay X38—Engine
E27—Engine Air Heater M1—Starter Motor Suppression Diode Harness-to-Engine Air
E28—Engine Air Heater Heater Harness
F65—Engine Air Heater Relay Connector
125 A Fuse
TX14826,000007A –19–24JUN03–2/2
9015B
10
53

092005
PN=417
System Diagrams
Engine Air Heater Harness (W7) Wiring Diagram (S.N. 590068— )

T191974 –UN–06OCT03
Engine Air Heater Harness (W7) Wiring Diagram

TX14826,0000079 –19–24JUN03–1/2

092005
PN=418
9015B-10-54 - A 9015B-10-54 - B
Engine A
T191974 –UN–0
TM2075 (03
9015B-10-54 - A
System Diagrams
ne Air Heater Harness (W7) Wiring Diagram (S.N. 590068— )

–UN–06OCT03
Engine Air Heater Harness (W7) Wiring Diagram

TX14826,0000079 –19–24JUN03–1/2

092005
PN=418
9015B-10-54 - B
System Diagrams
E26—Engine Air Heater K5—Engine Air Heater Relay V6—Engine Air Heater Relay X38—Engine
F65—Engine Air Heater Relay M1—Starter Motor Suppression Diode Harness-to-Engine Air
125 A Fuse Heater Harness
Connector
TX14826,0000079 –19–24JUN03–2/2
9015B
10
55

092005
PN=419
System Diagrams
Ride Control Harness (W9) Component Location (S.N. 590068— )
X44
9015B
10
56
B41
Y17
Y18
Y34
–UN–13OCT03
T191959
T191959
Ride Control Harness (W9) Component Location

092005
PN=420
System Diagrams
B41—Ride Control Pressure X44—Loader Frame Y17—Ride Control Boom Y34—Ride Control (On/Off)
Switch (closes with Harness-to-Ride Control Solenoid Solenoid
pressure) Harness Connector Y18—Ride Control (On/Off)
Solenoid
TX14826,000007E –19–24JUN03–2/2
9015B
10
57

092005
PN=421
System Diagrams
Ride Control Harness (W9) Wiring Diagram (S.N. 590068— )

T191975 –UN–06OCT03
Ride Control Harness (W9) Wiring Diagram

TX14826,000007D –19–24JUN03–1/2

092005
PN=422
9015B-10-58 - A 9015B-10-58 - B
Ride Co
T191975 –UN–0
TM2075 (03
9015B-10-58 - A
System Diagrams
Control Harness (W9) Wiring Diagram (S.N. 590068— )

–UN–06OCT03
Ride Control Harness (W9) Wiring Diagram

TX14826,000007D –19–24JUN03–1/2

092005
PN=422
9015B-10-58 - B
System Diagrams
B41—Ride Control Pressure X150—W9 Splice S2 Y17—Ride Control Boom Y34—Ride Control (On/Off)
Switch (closes with X151—W10 Splice S1 Solenoid Solenoid
pressure) Y18—Ride Control (On/Off)
X44—Loader Frame Solenoid
Harness-to-Ride Control
Harness Connector
TX14826,000007D –19–24JUN03–2/2
9015B
10
59

092005
PN=423
System Diagrams
Transmission Harness (W10) Component Location (S.N. 590068— )
X22
9015B
10
60
B28 B30 B29
X36
B20
B31
–UN–13OCT03
T191961
T191961
Transmission Harness (W10) Component Location

092005
PN=424
System Diagrams
B20—Transmission Oil Filter B29—Torque Converter Output X22—Load Center X36—Transmission

Restriction Switch Speed Sensor Harness-to-Transmission Harness-to-Transmission
B28—Torque Converter Input B30—Internal Clutch Speed Harness Connector Control Valve Harness
Speed Sensor (Engine Sensor Connector
Speed) B31—Transmission Output
Speed Sensor
TX14826,0000080 –19–24JUN03–2/2
9015B
10
61

092005
PN=425
System Diagrams
Transmission Harness (W10) Wiring Diagram (S.N. 590068— )

T191976 –UN–06OCT03
Transmission Harness (W10) Wiring Diagram

TX14826,000007F –19–24JUN03–1/2

092005
PN=426
9015B-10-62 - A 9015B-10-62 - B
Transmi
T191976 –UN–0
TM2075 (03
9015B-10-62 - A
System Diagrams
smission Harness (W10) Wiring Diagram (S.N. 590068— )

–UN–06OCT03
Transmission Harness (W10) Wiring Diagram

TX14826,000007F –19–24JUN03–1/2

092005
PN=426
9015B-10-62 - B
System Diagrams
B20—Transmission Oil Filter B29—Torque Converter Output X22—Load Center X152—W10 Splice S1
Restriction Switch Speed Sensor Harness-to-Transmission
B28—Torque Converter Input B30—Internal Clutch Speed Harness Connector
Speed Sensor (Engine Sensor X36—Transmission
Speed) B31—Transmission Output Harness-to-Transmission
Speed Sensor Control Valve Harness
Connector
TX14826,000007F –19–24JUN03–2/2
9015B
10
63

092005
PN=427
System Diagrams
Rear Frame Harness (W13) Component Location (S.N. 590068— )
E3
E5
E8
9015B E16
10
64
E9
E17
E10
H3
X39
–UN–10DEC03
T195480
T195480
Rear Frame Harness (W13) Component Location

092005
PN=428
System Diagrams
E3—Left Rear Turn Light E9—Right Tail Light E17—Right Rear Brake Light X39—Engine Frame
E5—Right Rear Turn light E10—License Plate Light H3—Back-Up Alarm Harness-to-Rear Frame
E8—Left Tail Light E16—Left Rear Brake Light Harness Connector
TX14826,0000082 –19–24JUN03–2/2
9015B
10
65

092005
PN=429
System Diagrams
Rear Frame Harness (W13) Wiring Diagram (S.N. 590068— )

T195481 –UN–29OCT03
Rear Frame Harness (W13) Wiring Diagram

TX14826,0000081 –19–24JUN03–1/2

092005
PN=430
9015B-10-66 - A 9015B-10-66 - B
Rear Fra
T195481 –UN–2
TM2075 (03
9015B-10-66 - A
System Diagrams
Frame Harness (W13) Wiring Diagram (S.N. 590068— )

–UN–29OCT03
Rear Frame Harness (W13) Wiring Diagram

TX14826,0000081 –19–24JUN03–1/2

092005
PN=430
9015B-10-66 - B
System Diagrams
E3—Left Rear Turn Light E10—License Plate Light X39—Engine Frame X153—W13 Splice S2
E5—Right Rear Turn light E16—Left Rear Brake Light Harness-to-Rear Frame X154—W13 Splice S3
E8—Left Tail Light E17—Right Rear Brake Light Harness Connector X155—W13 Splice S1
E9—Right Tail Light H3—Back-Up Alarm
TX14826,0000081 –19–24JUN03–2/2
9015B
10
67

092005
PN=431
System Diagrams
Cab Roof Harness (W19) Component Location (S.N. 590068— )
E22
S29
M5 S28
E15
E20
E23
9015B
10
68
E21
X6
X5
–UN–08DEC03
T191964
T191964
Cab Roof Harness (W19) Component Location
Continued on next page TX14826,000008B –19–24JUN03–1/2

092005
PN=432
System Diagrams
E15—Beacon Light E22—Left Rear Work Light S29—Door Switch (opens with X6—Load Center
E18—Dome Light E23—Right Rear Work Light door closed) Harness-to-Cab Roof
E20—Left Front Work Light M5—Rear Wiper Motor X5—Load Center Harness (6-pin) Connector
E21—Right Front Work Light S28—Dome Light Switch Harness-to-Cab Roof
TX14826,000008B –19–24JUN03–2/2
9015B
10
69

092005
PN=433
System Diagrams
Cab Roof Harness (W19) Wiring Diagram (S.N. 590068— )

T191978 –UN–06OCT03
Cab Roof Harness (W19) Wiring Diagram

TX14826,0000083 –19–24JUN03–1/2

092005
PN=434
9015B-10-70 - A 9015B-10-70 - B
Cab Roo
T191978 –UN–0
TM2075 (03
9015B-10-70 - A
System Diagrams
Roof Harness (W19) Wiring Diagram (S.N. 590068— )

–UN–06OCT03
Cab Roof Harness (W19) Wiring Diagram

TX14826,0000083 –19–24JUN03–1/2

092005
PN=434
9015B-10-70 - B
System Diagrams
E15—Beacon Light M5—Rear Wiper Motor X6—Load Center X157—W19 Splice S1

E20—Left Front Work Light S28—Dome Light Switch Harness-to-Cab Roof X158—W19 Splice S2
E21—Right Front Work Light S29—Door Switch (opens with Harness (6-pin) Connector X159—W19 Splice S3
E22—Left Rear Work Light door closed) X156—W13 Splice S5 X160—W20 Splice S1
E23—Right Rear Work Light X5—Load Center
Harness-to-Cab Roof
TX14826,0000083 –19–24JUN03–2/2
9015B
10
71

092005
PN=435
System Diagrams
Blower and A/C Harness (W20) Component Location (S.N. 590068— )
9015B
10
72
M6
X9
X8
B35
X52
B50 M7 X7
A3
–UN–13OCT03
T192383
T192383
Blower and A/C (W20) Component Location

092005
PN=436
System Diagrams
B35—Freeze Control Switch M6—Blower Motor X8—Load Center X52—A/C Pressure Switch
(opens with freeze M7—Pressurizer Motor Harness-to-Blower and Jumpered Connector
condition) R3—Blower Speed Resistor A/C Harness (2-pin)
B50—A/C Binary Pressure X7—Load Center Connector
Switch (opens with high Harness-to-Blower and X9—Load Center
and low pressures) A/C Harness (3-pin) Harness-to-Blower and
Connector A/C Harness (4-pin)
Connector
TX14826,0000085 –19–24JUN03–2/2
9015B
10
73

092005
PN=437
System Diagrams
Blower and A/C (W20) Wiring Diagram (S.N. 590068— )

T192382 –UN–06OCT03
Blower and A/C (W20) Wiring Diagram

TX14826,0000086 –19–24JUN03–1/2

092005
PN=438
9015B-10-74 - A 9015B-10-74 - B
Blower a
T192382 –UN–0
TM2075 (03
9015B-10-74 - A
System Diagrams
wer and A/C (W20) Wiring Diagram (S.N. 590068— )

–UN–06OCT03
Blower and A/C (W20) Wiring Diagram

TX14826,0000086 –19–24JUN03–1/2

092005
PN=438
9015B-10-74 - B
System Diagrams
B35—Freeze Control Switch M6—Blower Motor X8—Load Center X52—A/C Pressure Switch
(opens with freeze M7—Pressurizer Motor Harness-to-Blower and Jumpered Connector
condition) R3—Blower Speed Resistor A/C Harness (2-pin) X161—W20 Splice S1
B50—A/C Binary Pressure X7—Load Center Connector
Switch (opens with high Harness-to-Blower and X9—Load Center
and low pressures) A/C Harness (3-pin) Harness-to-Blower and
Connector A/C Harness (4-pin)
Connector
TX14826,0000086 –19–24JUN03–2/2
9015B
10
75

092005
PN=439
System Diagrams
Radio Harness (W34) Component Location (S.N. 590068— )
9015B
10
76
–UN–12SEP03
T192814
Harness Component Location


092005
PN=440
System Diagrams
A5—12 V Radio G7—24 V to 12 V Voltage W1—Antenna X34—Load Center Harness to

B42—Left Speaker Converter Radio Harness
B43—Right Speaker Connector
TX14826,0000089 –19–24JUN03–2/2
9015B
10
77

092005
PN=441
System Diagrams
Radio Harness (W34) Wiring Diagram (S.N. 590068— )

T192813 –UN–06OCT03
TX14826,000008A –19–24JUN03–1/2

092005
PN=442
9015B-10-78 - A 9015B-10-78 - B
Radio H
T192813 –UN–0
TM2075 (03
9015B-10-78 - A
System Diagrams
o Harness (W34) Wiring Diagram (S.N. 590068— )

–UN–06OCT03
TX14826,000008A –19–24JUN03–1/2

092005
PN=442
9015B-10-78 - B
System Diagrams
A5—12 V Radio G7—24 V to 12 V Voltage X34—Load Center Harness to X165—W34 Splice S1

B42—Left Speaker Converter Radio Harness
B43—Right Speaker Connector
TX14826,000008A –19–24JUN03–2/2
9015B
10
79

092005
PN=443
System Diagrams
9015B
10
80

092005
PN=444
Group 15
Starting and Charging Circuit Theory of Operation (S.N. 590068— )
T193463 –19–10NOV03
OUT1738,0000146 –19–18JUN03–1/2

092005
PN=445
9015B-15-1 - A 9015B-15-1 - B
Group 15
Starting and Charging Circuit Theory of Operation (S.N. 590068— )

T193463 –19–10NOV03
OUT1738,0000146 –19–18JUN03–1/2

092005
PN=445
9015B-15-1 - A
1/2
der
92005
445
9015B-15-1 - B
Starting and Power Circuit 12A. Power is applied through start relay 5 A fuse
(F41) to VEC terminal 12H and start relay 3 A diode
Battery power is supplied to the starter motor (M1), (V4). Power is applied from VEC terminal 12H to the
key switch (S1), start relay (K3), ignition relay (K4), start relay, energizing the relay. With the start relay
and Vehicle Electrical Center (VEC) (G8). Power can energized, battery power is supplied to the starter coil
be disconnected by the manual battery disconnect suppression 5 A diode (V1) and starter motor solenoid,
(S2). When the key switch is placed in the on position, causing the starter to crank. The start relay 3 A diode
power is applied from the key switch terminal IGN to and starter coil suppression 5 A diode, both located in
VEC terminal 3F. Power is applied through reverse the VEC, suppress voltage spikes caused by the relay
polarity 3 A diode (V7) to VEC terminal 2G. The or solenoid coil energizing and de-energizing.
reverse polarity diode prevents the ignition relay from
energizing if the polarity on the system is reversed Charging Circuit
(batteries or starter installed incorrectly). Power is
applied from VEC terminal 2G to the ignition relay , When the key switch is in the on position, ignition
energizing the relay. With the ignition relay energized, power is applied through alternator excitation 5 A fuse
battery power is supplied to VEC terminals 6A and 6C, (F53) and alternator excitation 3 A diode (V5) in the
supplying power to all ignition power circuits. Ignition VEC to alternator terminal D+C. When the engine is
relay 3 A diode (V3), located in the VEC, suppresses running and alternator is producing power, the
voltage spikes caused by the relay coil energizing and alternator charges the batteries and provides power to
de-energizing. the unswitched and ignition power circuits.
9015B When the key switch is placed in the start position,

15 power is applied from the ST terminal to VEC terminal
2
OUT1738,0000146 –19–18JUN03–2/2

092005
PN=446
Controller Area Network (CAN) Theory of Operation (S.N. 590068— )

T193465 –19–10NOV03
OUT1738,0000147 –19–18JUN03–1/2

092005
PN=447
9015B-15-3 - A 9015B-15-3 - B
Controller Area Network (CAN) Theory of Operation (S.N. 590068— )

T193465 –19–10NOV03
OUT1738,0000147 –19–18JUN03–1/2

092005
PN=447
9015B-15-3 - A
1/2
der
92005
447
9015B-15-3 - B
This machine utilizes a controller area network (CAN) interference caused by many electrical sources. The
on which devices communicate. The Engine Control devices on the CAN are connected via three wires
Unit (ECU), Transmission Control Unit (TCU), CAN weaved together called a twisted triple. The twisted
Monitor Unit (CMU), Flex Load Controller (FLC), and triple consists of a high voltage signal wire, a low
Sealed Switch Module (SSM) are all connected to the voltage signal wire, and a ground wire. This method
CAN. Operations and functions of these individual reduces interference and helps the devices
devices are covered separately. communicate with minimal errors.
• See CAN Monitor Unit (CMU) Circuit Theory of There are a few more components connected to the
Operation (S.N. 590068— ). (Group 9015B-10.) CAN. CAN Termination Node R1 and CAN
• See Engine Control Unit (ECU) Circuit Theory of Termination Node R2 are 120 [OHgr ] resistors which
Operation (S.N. 590068— ). (Group 9015B-10.) are connected on opposite ends of the bus to avoid
• See Flex Load Controller (FLC) Circuit Theory of signal errors. The Service ADVISOR Diagnostic
Operation (S.N. 590068— ). (Group 9015B-10.) Connector (X1) is provided for machine diagnostic
• See Transmission Control Unit (TCU) Circuit Theory purposes. See SERVICE ADVISOR System Computer
of Operation (S.N. 590068— ). (Group 9015B-10.) Connection for information on connecting to J-Series
loaders (S.N. 590068— ).
The devices on the CAN are communicating on a high
frequency, which makes the network susceptible to
9015B
15
4
OUT1738,0000147 –19–18JUN03–2/2

092005
PN=448
Engine Control Unit (ECU) Circuit Theory of Operation (S.N. 590068— )

T196322 –19–21NOV03
OUT1738,0000148 –19–14AUG03–1/4

092005
PN=449
9015B-15-5 - A 9015B-15-5 - B 9015B-15-5 - C
Engine Control Unit (ECU) Circuit Theory of Operation (S.N. 590068— )

T196322 –19–21NOV03
OUT1738,0000148 –19–
TM2075 (03MAR05) 9015B-15-5 644J and 72
9015B-15-5 - A
8 –19–14AUG03–1/4
nd 724J Loader
092005
PN=449
9015B-15-5 - B
9015B-15-5 - C
9015B-15-5 - Blank
The engine control unit (ECU) (A1) uses the the ECU at pins W1 and W2. The ECU uses this
information received by its sensors to determine the signal to determine when the number one cylinder is at
correct amount of fuel and injection timing based on top dead center. The ECU also uses this signal to
load, temperatures, and operator input. Some of the calculate engine speed. For more information on the
data calculated by the ECU is broadcast across CAN crankshaft position sensor, see Electrical Component
to other controllers. The ECU also detects faults in the Specifications (S.N. 590068— ). (Group 9015B-20.)
sensors or abnormal operating conditions.
Camshaft Position Sensor
Analog Throttle Position Sensor
The camshaft position sensor (B3) is an inductive
The ECU senses the amount of requested throttle with pickup located in the high pressure fuel pump. The
the analog throttle position sensor (B14). The analog signal is produced by notches on the auxiliary gear of
throttle position sensor supplies the ECU with a the high pressure fuel pump and is sensed by the ECU
variable resistance based on throttle pedal position. at pins X1 and W3. The ECU uses this signal to
The ECU supplies 5 volts at pin N1 and resistance is determine which cylinder is approaching top dead
sensed between pins R2 and N3. The ECU broadcasts center. For more information on the camshaft position
the throttle position across CAN to the CAN Monitor sensor, see Electrical Component Specifications (S.N.
Unit (CMU) (H2) and the flex load controller (FLC) 590068— ). (Group 9015B-20.)
(A2).
Engine Coolant Temperature Sensor
Engine Air Heater
9015B The engine coolant temperature sensor (B1) is a
15 When the ECU senses the engine temperature is cold variable resistance temperature sensor. The resistance
6
enough to require a start aid, the ECU applies power is sensed at pins X2 and P2. The ECU broadcasts the
from pin J3 to the engine heater relay (K5), energizing engine coolant temperature across the CAN to the
it. For more information on the engine air heater CMU. The CMU displays the temperature on the
circuit, see System Functional Schematic and Section engine coolant temperature gauge. The engine coolant
Legend (S.N. 590068— ). (9015B-10.) temperature is also used by the FLC in calculating
proportional fan speed. See Flex Load Controller (FLC)
Engine Air Filter Restriction Switch Circuit Theory of Operation (S.N. 590068— ) for more
information on the proportional fan circuit. (Group
The engine air filter restriction switch (B19) is a 9015B-15.) For more information on the engine coolant
normally open switch that will close when a restriction temperature sensor, see Electrical Component
is detected. When the switch closes, switched power is Specifications (S.N. 590068— ). (Group 9015B-20.)
supplied from restriction switch/radio ignition power 10
A fuse (F11) to ECU pin F3. The ECU broadcasts the The engine coolant temperature can cause engine fuel
engine air filter restriction switch state across CAN to derate conditions. If the engine coolant temperature
the CMU. reaches 230°F (110°C), the ECU will derate fuel by 2%
per minute up to 20%. If the coolant temperature
Crankshaft Position Sensor reaches 239°F (115°C), the ECU will derate fuel by
20% per minute up to 40%. If the coolant temperature
The crankshaft position sensor (B4) is an inductive drops below the derate threshold temperatures, the
pickup located at the front of the engine. The signal is ECU will recover fuel delivery by the same rate until
produced by teeth on a timing gear and is sensed by power is fully restored.
Continued on next page OUT1738,0000148 –19–14AUG03–2/4

092005
PN=450
Manifold Air Temperature (MAT) Sensor to monitor the fuel system pressure and apply derate
conditions when needed. For more information on the
The Manifold Air Temperature (MAT) sensor (B7) is a fuel rail pressure sensor, see Electrical Component
variable resistance temperature sensor. The resistance Specifications (S.N. 590068— ). (Group 9015B-20.)
is sensed at pins Y2 and N3. The ECU broadcasts the
MAT across the CAN to the CMU. The MAT is also The fuel rail pressure sensor can cause an engine fuel
used by the FLC in calculating proportional fan speed. delivery derate if a problem in the harness wiring or
See Flex Load Controller (FLC) Circuit Theory of sensor occurs. If the ECU senses a value that is out of
Operation (S.N. 590068—) for more information on the valid range, the ECU will derate fuel delivery by 50%.
proportional fan circuit. (9015B-15.) For more Once the problem is corrected, fuel delivery will be
information on the MAT sensor, see Electrical recovered to full power.
Component Specifications (S.N. 590068— ). (Group
9015B-20.) Fuel Temperature Sensor
The manifold air temperature can cause an engine fuel The fuel temperature sensor (B5) is a variable
derate condition if it reaches 190°F (88°C). The ECU resistance temperature sensor. The resistance is
will derate fuel 2% per minute up to 20%. If the sensed at pins X3 and P2. The ECU broadcasts the
manifold air temperature falls below the derate fuel temperature across the CAN to the CMU and FLC.
temperature, the ECU will recovery fuel delivery 2% For more information on the fuel temperature sensor,
per minute until power is fully restored. see Electrical Component Specifications (S.N.
590068— ). (Group 9015B-20.)
Water In Fuel (WIF) Sensor 9015B
Engine Oil Pressure Sensor 15
7
The Water In Fuel (WIF) Sensor (B48) is a variable
resistance sensor. The WIF sensor measures the The engine oil pressure sensor (B23) is a variable
amount of resistance of the fluid in the water separator resistance pressure sensor. Power is applied to the
bowl. Since water is a better conductor of electricity sensor from ECU pin P1 and resistance is sensed at
than fuel is, if water is present in the separator bowl, pins T2 and P2. The ECU uses the engine oil pressure
the ECU senses a resistance drop between pins Y3 sensor to monitor the oil pressure and apply derate
and N3. For more information on the WIF sensor, see conditions when needed. The ECU broadcasts the
Electrical Component Specifications (S.N. 590068— ). engine oil pressure across the CAN to the CMU and
(Group 9015B-20.) FLC. For more information on the engine oil pressure
sensor, see Electrical Component Specifications (S.N.
The water in fuel sensor can cause an engine fuel 590068— ). (Group 9015B-20.)
delivery derate if water is sensed in the fuel. If the
ECU senses too low of resistance, the ECU will derate The engine oil pressure can cause an engine fuel
fuel delivery by 40% per minute. Once the problem is delivery derate if the pressure falls below the first
corrected, fuel delivery will be recovered to full power. threshold pressure. The ECU will derate the fuel
delivery by 20% per minute up to 40% if the pressure
Fuel Rail Pressure Sensor falls below the first threshold pressure. If the pressure
falls below the second threshold pressure, the ECU
The fuel rail pressure sensor (B49) is a variable will derate fuel delivery by 40% per minute up to 60%.
resistance pressure sensor. The ECU supplies the If the oil pressure increases past the first threshold
sensor 5 volts at pin R3 and resistance is sensed at pressure, the ECU will recover fuel delivery by 20%
pins P3 and R1. The ECU uses the fuel rail pressure per minute until full power is reached.

092005
PN=451
High Pressure Fuel Pump Solenoids See Pump Control Valves (PCVs) for more
information. (CTM255.)
The high pressure fuel pump solenoids (Y8, Y9) are
located on the high pressure fuel pump. The ECU Electronic Injectors
applies a common voltage at pin J1 to the solenoids
and controls the ground signals at pins K2 and K3 to The ECU controls the injection timing and the amount
regulate delivery of fuel to the high pressure common of fuel injected by energizing and de-energizing the
rail (HPCR). When the solenoids are energized, fuel is electronic injectors (Y21—Y26). For more information
allowed to discharge from the fuel outlet on the high on the electronic injectors, see Electronic Injector (EI)
pressure fuel pump to the HPCR. Operation. (CTM255.)
OUT1738,0000148 –19–14AUG03–4/4
9015B
15
8

092005
PN=452
Flex Load Controller (FLC) Circuit Theory of Operation (S.N. 590068— )

T196317 –19–12DEC03
OUT1738,0000149 –19–02FEB05–1/18

092005
PN=453
9015B-15-9 - A 9015B-15-9 - B
Flex Load Controller (FLC) Circuit Theory of Operation (S.N. 590068— )

T196317 –19–12DEC03
OUT1738,0000149 –19–02FEB05–1/18

092005
PN=453
9015B-15-9 - A
18
der
92005
453
9015B-15-9 - B
The Flex Load Controller (FLC) (A2) is a solid state FLC battery power 10 A fuse (F21). Ground is supplied
device which controls and monitors the electrical loads through pins L2 and M2 of connector X41 and pins H1
on the machine and vehicle operations. The FLC also and H2 of connector X42.
provides diagnostics for the systems it controls. See
Flex Load Controller (FLC) Fault Exceptions (S.N. The FLC has inputs for machine sensors which it
590068— ) for more information on the operation of shares with other units over CAN. See Controller Area
the output drivers. (Group 9015B-20.) Network (CAN) Theory of Operation (S.N. 590068— ).
(Group 9015B-15.)
The FLC controls the following systems:
Steering System Pressure Switch (B25)
• Secondary Steering
• Ride Control This normally open switch applies ignition power from
• Spin Control brake/steering pressure switch 5 A fuse to pin C1 of
• Pilot Enable connector X41 (J2) when closed. This switch closes
• Pin Disconnect when normal operating steering system pressure is
• Axle Disconnect present. When secondary steering is equipped, if the
• Reverse Fan engine is running and the steering system pressure
• Proportional Fan switch opens, the FLC applies power from connector
• Return-to-Carry X42 (J3) pin F1 for the secondary steering pump motor
• Boom Height Kickout (M8). The FLC will also broadcast the secondary
• Return-to-Dig steering message across CAN to the CAN Monitor Unit
9015B • Turn Signal Lights (CMU). The CMU will illuminate the secondary steering
15 • 4-Way Flashers indicator light when the system is active. For more
10
• Drive Lights information on the steering system pressure switch,
• Marker/Tail Lights see Electrical Component Specifications (S.N.
• Brake Lights 590068— ). (Group 9015B-20.)
• Work Lights
• Beacon Light Service Brake Pressure Switch, Accumulator
• Air Conditioning Charge (B27)
• Front Wiper Motor
• Front Washer Pump This normally open switch applies ignition power from
• Rear Wiper Motor brake/steering pressure switch 5 A fuse to pin E2 of
• Rear Washer Pump connector X40 (J1) when closed. This switch closes
when normal operating service brake pressure is
The FLC is powered by ignition power at pins G3, G4, present. The FLC broadcasts the service brake
H3, and H4 of connector X40 (J1), pins L3, L4, M3, pressure switch message across the CAN to the CAN
and M4 of connector X41 (J2), and pins G1, G2, H3, Monitor Unit (CMU). When the switch opens, the CMU
and H4 of connector X42 (J3). The FLC receives an will illuminate the brake pressure indicator light. For
ignition power signal at pin M1 of connector X41 more information on the service brake pressure switch,
through FLC ignition power 5 A fuse (F15). Battery see Electrical Component Specifications (S.N.
power is supplied to pin L1 of connector X41 through 590068— ). (Group 9015B-20.)
Continued on next page OUT1738,0000149 –19–02FEB05–2/18

092005
PN=454
Hydraulic Oil Temperature Sensor (B15) The required hydraulic system pressure and engine
rpm for each setting are:
This variable resistance temperature sensor is
grounded at pin K2 of connector X41 (J2) and the Setting Hydraulic System Engine Speed
resistance is sensed at pin E4 of connector X42 (J3). Pressure
The FLC broadcasts the hydraulic oil temperature 1 22 753 kPa 1900 rpm
across the CAN to the CAN Monitor Unit (CMU). The 227.5 bar
3300 psi
CMU displays the temperature on the hydraulic oil
temperature gauge. The hydraulic oil temperature is 2 22 753 kPa 1800 rpm
227.5 bar
also used in calculating proportional fan speed. More 3300 psi
information on the proportional fan circuit can be found
3 21 718 kPa 1700 rpm
later in this group. For more information on the 217.2 bar
hydraulic oil temperature sensor, see Electrical 3150 psi
Component Specifications (S.N. 590068— ). (Group 4 19 994 kPa 1600 rpm
9015B-20.) 200 bar
2900 psi
Hydraulic System Pressure Sensor (B8)
Hydraulic Oil Filter Restriction Switch (B21)
The FLC uses the hydraulic system pressure sensor
(B8) to monitor the hydraulic pump output pressure This normally open switch applies ground to pin F2 of
and lower engine rpm as required by the spin control connector X41 (J2) when closed. This switch closes
setting. The FLC applies power from pin K4 of when the hydraulic oil differential pressure at the filter 9015B
connector X41 (J2) to hydraulic system pressure 15
is greater than specification and the filter bypass valve
11
sensor and resistance is sensed at pins D3 and K3 of opens. The FLC broadcasts the hydraulic oil filter
connector X41 (J2). For more information on the restriction switch message across the CAN to the CAN
hydraulic system pressure sensor, see Electrical Monitor Unit (CMU). When the switch closes, the CMU
Component Specifications (S.N. 590068— ). (Group will illuminate the hydraulic oil filter restriction indicator
9015B-20.) light.
Spin control has four settings which can be selected Start Signal
by pressing the spin control switch (S33) on the SSM.
Once the hydraulic system pressure reaches a The FLC senses when the starter is cranked to
predetermined value (determined by the setting), the determine machine state. The FLC input pin C1 on
FLC broadcasts a requested engine speed across the connector X40 (J1) is connected to the key switch start
CAN to the ECU. The reduced engine speed reduces signal on the start relay (K3).
rim pulling force at the wheel rims, allowing the boom
to lift easier.

092005
PN=455
12 Volt Center Tap voltage across CAN to the CAN Monitor Unit (CMU).
The CMU uses the two data items to calculate the
The FLC measures the battery voltage of one battery voltage level of the two batteries. These values can be
at pin F1 of connector X40 (J1). The FLC broadcasts read in the battery monitor menu of the CMU.
the single battery voltage along with the 24 volt system
9015B
15
12

092005
PN=456
T193255 –19–25NOV03

092005
PN=457
9015B-15-13 - A 9015B-15-13 - B 9015B-15-13 - C
T193255 –19–25NOV03
Continued on next page OUT1738,0000149 –19–
TM2075 (03MAR05) 9015B-15-13 644J and 72
9015B-15-13 - A
–19–02FEB05–5/18
nd 724J Loader
092005
PN=457
9015B-15-13 - B
9015B-15-13 - C
9015B-15-13 - Blank
The FLC controls many hydraulic functions on the valid for the machine options available or machine
machine with the use of solenoids. These functions are state, the input is ignored. If the input is valid, the
controlled through the pilot controller (A4) and the appropriate function is activated and the SSM receives
sealed switch module (SSM) (A6). The SSM is a confirmation that the function is activated and
device that receives input through momentary illuminates the appropriate LED to indicate that the
switches, and broadcasts the button selection across function has been activated. Ignition power is applied
CAN to the CAN Monitor Unit (CMU) and FLC. These to the SSM through CMU/SSM ignition power 5 A fuse
respective controllers interpret the signals and (F13).
determine if the input is valid or not. If the input is not
9015B
15
14

092005
PN=458
Ride Control
The ride control circuit consists of three solenoids and a

pressure switch. The ride control (on/off) solenoids (Y18
and Y34) are wired in parallel and are controlled by FLC
pin G4 on connector X41 (J2). Ignition power for the
solenoids is supplied to the FLC at pins L3 and M3 on
connector X41 (J2). These solenoids are energized when
the ride control system is in manual mode or when active
in auto mode. The ride control boom solenoid (Y17) is
controlled by the ride control pressure switch (B41). The
ride control pressure switch is a normally open switch,
which closes when bucket dump pilot pressure is present.
When the keyswitch is in the on or start position, power is
–UN–26JAN05
applied from FLC pin E4 on connector X41 (J2) to the ride
control pressure switch. When bucket dump is actuated,
the ride control pressure switch closes and energizes the
ride control boom solenoid. When the ride control boom
T207268
solenoid is energized, the oil in the boom cylinder head
end cannot flow into the accumulator.
Ride Control Valve
To turn ride control on in manual mode, press the ride 9015B
1—Y34 Ride Control (on/off) Solenoid 15
control switch (S31) on the SSM until one LED is
2—Y17 Ride Control Boom Solenoid 15
illuminated. To turn on auto mode, press the ride control 3—Y18 Ride Control (on/off) Solenoid
switch once more so two LEDs are illuminated. While in
auto mode, ride control will remain off until machine
ground speed is at or above 3.7 mph (6 km/h).
For more information on the ride control system, see Ride

Control Operation. (Group 9025-05.)
Pilot Enable/Boom Down
The pilot enable solenoid (Y14) and the accumulator

solenoid (Y15) are wired in parallel to FLC pin E1 on
connector X42 (J3). Ignition power for the solenoid is
supplied to the FLC at pins G1 and G2 on connector X42
(J3). When the key switch is on and the engine is running,
the hydraulic functions can be enabled or disabled by
pressing the pilot enable/boom down switch (S18). When
the LED is illuminated, the pilot enable solenoid and the
accumulator solenoid are energized, allowing the hydraulic
functions to be actuated.

092005
PN=459
When the key switch is on and the engine is off, the

hydraulic controls are locked. When the pilot enable/boom
down switch is held down, the boom down hydraulic
function can be actuated to lower the boom.
For more information on these functions, see Pressure

Reducing Valve Operation (S.N. 590068— ). (Group
9025-05.)
Return-to-Dig, Boom Height Kickout, and

Return-to-Carry
NOTE: Pilot enable must be on before return-to-dig,

boom height kickout, return-to-carry or float
detents will turn.
The pilot controller (A4) controls the boom and bucket

hydraulic functions. The pilot controller contains
electromagnetic detent coils for the boom height kickout,
return-to-dig, and return-to-carry.
9015B The return-to-dig function can be turned on by cycling the

15 return-to-dig enable switch (S42) on the SSM. When the
16
left LED is illuminated return-to-dig is enabled. The right
LED is used for Powerllel linkage machines. The
return-to-dig switch (S17) is a metal sensing proximity
switch that draws power from the VEC restriction switches
10 A fuse (F11). When the return-to-dig function is
activated and the bucket is in the dump position the
return-to-dig switch (S17) senses the metal adjustable bar
and the switch is closed. Power flows across the closed
return-to-dig switch (S17) to the FLC pin C2 on connector
X41 (J2) (Red). The FLC will send ignition power received
from pins L4 and M4 of connector X41 (J2) (Red) to
energize the return-to-dig detent coil from pin H4 of
connector X41 (J2) (Red). If bucket rollback is fully
actuated, the return-to-dig detent coil will magnetically
hold the pilot controller in that position until the
return-to-dig switch no longer senses the metal adjustable
rod metal. The return-to-dig switch (S17) will open and
remove power to the FLC. The FLC will then remove
power from the return-to-dig detent coil and the pilot
controller will return to neutral position. To set the
return-to-dig position, see Return-to-Dig Adjustment S.N.
590068 — ) . (Group 9015B-20.)

092005
PN=460
The analog BHKO/RTC sensor (B45) is located on the

loader frame and provides the FLC with a variable
resistance referencing the boom position. The analog
BHKO/RTC sensor is connected to FLC pins K1, K2, and
E3 on connector X41 (J2).
The boom height kickout function can be turned on by

pressing the boom height kickout switch (S39) on the
SSM. When the LED is illuminated, the boom height
kickout function is enabled. The FLC uses the analog
BHKO/RTC sensor to detect the position of the boom and
if the position is lower than the preset kickout position, the
FLC will apply power from pin A2 of connector X42 (J3) to
the boom height kickout detent coil. Ignition power for the
boom height kickout detent coil is supplied to the FLC at
pins H3 and H4 on connector X42 (J3). If boom raise is
fully actuated, the boom height kickout detent coil will
magnetically hold the pilot controller in that position until
the boom reaches the preset position. The FLC will then
remove power from the boom height kickout detent coil
and the pilot controller will return to neutral. To set the
boom height kickout position, see Boom Height 9015B
Kickout/Return-to-Carry Adjustment (S.N. 590068— ). 15
17
(Group 9015B-20.)
The return-to-carry function can be turned on by pressing

the return-to-carry switch (S40) on the SSM. When the
LED is illuminated, the return-to-carry function is enabled.
The FLC uses the analog BHKO/RTC sensor to detect the
position of the boom and if the position is higher than the
preset kickout position, the FLC will apply power from pin
D4 of connector X41 (J2) to the return-to-carry/float detent
coil. Ignition power for the return-to-carry/float detent coil
is supplied to the FLC at pins L3 and M3 on connector
X41 (J2). If boom lower is fully actuated, the
return-to-carry/float detent coil will magnetically hold the
pilot controller in that position until the boom reaches the
preset position. The FLC will then remove power from the
return-to-carry/float detent coil and the pilot controller will
return to neutral. To set the return-to-carry position, see
Boom Height Kickout/Return-to-Carry Adjustment (S.N.
590068— ). (Group 9015B-20.)

092005
PN=461
To use the float function, the return-to-carry function must

be disabled. The FLC will apply power from pin D4 of
connector X41 (J2) to the return-to-carry/float detent coil.
Ignition power for the return-to-carry/float detent coil is
supplied to the FLC at pins L3 and M3 on connector X41
(J2). If boom lower is fully actuated, the
return-to-carry/float detent coil will magnetically hold the
pilot controller in that position.
Axle Disconnect
Mechanical power to the front axle can be disconnected

by pressing and holding down the axle disconnect switch
(S35) on the SSM. When the LED is illuminated, the front
axle is disconnected. When the axle disconnect is active,
the FLC applies power from pin B4 of connector X41 (J2)
to the axle disconnect solenoid (Y28). When the solenoid
is energized, hydraulic oil releases the axle coupling,
disconnecting the axle. For more information on the axle
disconnect function, see Pin and Axle Disconnect
Operation. (Group 9025-05.)
9015B
15 Pin Disconnect
18
On equipped machines, the front attachment can be

detached by pressing and holding down the pin
disconnect switch (S12) on the SSM. When the LED is
illuminated, the pins are disengaged and the FLC applies
power from pin F4 of connector X41 (J2) to the pin
disconnect solenoid (Y20). When the solenoid is
energized, hydraulic oil retracts the pins in the front
coupling, disconnecting the attachment. For more
information on the pin disconnect function, see Pin and
Axle Disconnect Operation. (Group 9025-05.)

092005
PN=462
Proportional Fan
The proportional fan controls the cooling capacity of the

cooling package by varying the speed of the fan. The FLC
automatically controls the speed of the fan by monitoring
hydraulic oil temperature, engine coolant temperature,
transmission oil temperature, manifold air temperature,
and air conditioning state (on/off). The hydraulic oil
temperature sensor and A/C compressor clutch (Y16) are
hard-wired to the FLC. The engine coolant temperature
sensor (B1) and manifold air temperature sensor (B7) are
hard-wired to the engine control unit (ECU) (A1) and
broadcasted across CAN to the FLC. The transmission oil
temperature sensor is hard-wired to the transmission
control unit (TCU) (A3) and broadcasted across CAN to
the FLC.
The FLC uses certain reference values for determining fan

speed. The first set of values the FLC interprets is the
hydraulic oil temperature, engine coolant temperature, and
the transmission oil temperature. From the table below,
the FLC selects the fastest fan speed at which all three 9015B
temperatures are below the specified temperatures. 15
19
Fan Speed Hydraulic Oil Engine Coolant Transmission
Temperature Temperature Oil
Temperature
500 RPM 62.8°C 90°C 82.2°C
145°F 194°F 180°F
1700 RPM 96.1°C 101.7°C 101.7°C
205°F 215°F 215°F
When the manifold air temperature is above 50°C (122°F),

the FLC considers the differential temperature between
engine coolant temperature and manifold air temperature
as another item to calculate fan speed with. From the
table below, the FLC selects the fastest fan speed at
which all four temperatures are below the specified
temperatures.

092005
PN=463
Fan Speed Hydraulic Engine Transmission Engine

Oil Coolant Oil Coolant
Temperature Temperature Temperature Temperature
- Manifold
Air
Temperature
500 RPM 62.8°C 90°C 82.2°C 3.3°C
145°F 194°F 180°F 38°F
1700 RPM 96.1°C 101.7°C 101.7°C 17.2°C
205°F 215°F 215°F 63°F
Once the above fan speed is selected, the FLC derates

fan speed based on manifold air temperature. The
percentages are based on temperatures between 50°C
(122°F) and 60°C (140°F).
% Speed Manifold Air Temperature

0% 50°C
122°F
50% 55°C
131°F
100% 60°C
9015B 140°F
15
20
If the manifold air temperature is 60°C (140°F) or higher,
the fan will operate at 100% of the rated speed based on
fluid and differential air temperature.
When the air conditioner is on, the minimum fan speed is

determined by the ambient air temperature.
Fan Speed Ambient Air Temperature

550 RPM 72°C
161.6°F
1400 RPM 112°C
233.6°F
The proportional fan solenoid (Y37) is controlled by pins

C4 and D4 on connector X42 (J3). Ignition power for the
solenoid is supplied to the FLC at pins H3 and H4 on
connector X42 (J3). The amount of current the FLC drives
the solenoid is inversely dependant on the calculated fan
speed. The current supplied to the solenoid ranges from
600 mA (545 RPM) to 0 mA (1900 RPM). See Fan Drive
Operation for more information. (Group 9025-05.)

092005
PN=464
Reverse Fan
The reverse fan function reverses the fan direction to

purge the cooling system of debris. The reverse fan
function can be operated in manual and automatic mode.
Automatic mode is the default and will automatically
reverse directions every 30 minutes unless manual mode
is activated. Manual mode is activated by pressing the
reverse fan switch (S41) on the SSM and the LED will
illuminate. Once the manual reverse cycle is complete, the
LED on the reverse fan switch will become unlit and the
function will return to automatic mode.
When the internal 30 minute timer in the FLC reaches full

count or if manual mode is selected, the FLC will begin
the reversing sequence. The reversing function works in
conjunction with the proportional fan solenoid. The FLC
ramps up the proportional fan solenoid current to slow the
fan down to minimum fan speed (approximately 500
RPM). Once the fan speed is at a minimum, the FLC will
apply power from pin C4 on connector X41 (J2) to the
reverse fan solenoid (Y38), reversing the fan drive 9015B
direction. Once power is applied to the reverse fan 15
21
solenoid, the FLC will ramp down the current applied to
the proportional fan solenoid until maximum fan speed
(approximately 1900 RPM) is reached. The FLC will
operate the fan at maximum speed for 15 seconds then
ramp up the proportional fan solenoid current until the fan
is at minimum speed. Once the fan is slowed down to
minimum speed, the FLC will remove power from the
reverse fan solenoid then ramp current down to the
normal current for the normal operating fan speed.
The reverse fan sequence cannot be activated again for

one minute after it was completed. If the reverse fan was
in automatic mode prior to manual mode being activated,
the 30 minute timer is stopped then started again after the
reverse fan sequence is completed. See Fan Drive
Operation for more information. (Group 9025-05.)

092005
PN=465
T204682 –19–21DEC04
Flex Load Controller (FLC) Light Circuit

092005
PN=466
9015B-15-22 - A 9015B-15-22 - B 9015B-15-22 - C
9015B-15-22 - A
T204682 –19–21DEC04
TM2075 (03MAR05)
9015B-15-22 - B
Flex Load Controller (FLC) Light Circuit
9015B-15-22 644J and 724J Loader

092005
PN=466
9015B-15-22 - C
9015B-15-22 - Blank
Marker and Drive Lights Work Lights
The drive light switch (S26) on the SSM has three The work light switch (S30) on the SSM has four
modes: off, marker lights, and marker and drive lights. modes: off, front, front/rear, and front/rear/docking.
When the left LED is illuminated, the FLC applies When the left LED is illuminated, the FLC applies
power from pin D2 on connector X42 (J3) to the front power from pins C3 and C4 of connector X40 (J1) to
marker lights (E6 and E7), the taillights (E8 and E9), left front work light (E20) and right front work light
and the license plate light (E10). Ignition power for (E21). Ignition power is supplied for the front work
these lights is supplied to the FLC at pins H3 and H4 lights is supplied to the FLC at pins L3 and M3 on
on connector X42 (J3). When both LEDs are connector X41 (J2). When the left and center LEDs
illuminated, the FLC also applies power from pins A3 are illuminated, the FLC applies power to pins B3 and
and A4 on connector X40 (J1) to the front drive lights B4 of connector X40 (J1) to left rear work light (E22)
(E11 and E12). Ignition power for these lights is and right rear work light (E23) in addition to the front
supplied to the FLC at pins L4 and M4 on connector work lights. Ignition power for the rear work lights is
X41 (J2). supplied to the FLC at pins L4 and M4 on connector
X42 (J3). When all three LEDs are illuminated, the
Turn Signal Lights and 4-Way Flashers FLC applies power to pins F3 and F4 of connector X40
(J1) to left docking light (E24) and right docking light
When the operator activates the turn signals, the CAN (E25) in addition to the front and rear work lights.
Monitor Unit (CMU) broadcasts the signal across CAN Ignition power for the docking lights is supplied to the
to the FLC. The FLC interprets the signal and applies FLC at pins H3 and H4 on connector X40 (J1).
power to the appropriate lights. If the left turn signal is 9015B
selected, the FLC applies alternating power at a Brake Lights 15
23
predetermined rate from pin B2 on connector X42 (J3)
to left front turn light (E2) and left rear turn light (E3). If The brake light pressure switch (B40) is a normally
the right turn signal is selected, the FLC applies open switch that closes when brake pressure is
alternating power at a predetermined rate from pin C2 present. When the brake light pressure switch closes,
on connector X42 (J3) to right front turn light (E4) and battery power is applied from brake light pressure
right rear turn light (E5). Battery power for the turn switch 5 A fuse (F02) to FLC pin A4 on connector X41
signal lights is supplied to the FLC at pin L1 on (J2). The FLC then applies power from pin B4 to left
connector X41 (J2). brake light (E16) and right brake light (E17). Battery
power for the brake lights is supplied to the FLC at pin
When the 4-way flasher switch (S24) is turned on, L1 on connector X41 (J2). If the key switch is off when
battery power is applied from flashers 5 A fuse (F01) the brake light pressure switch is turned on, the FLC
to FLC pin D2 on connector X41 (J2). The FLC applies will turn on to power the brake lights.
alternating power at a predetermined rate from pin B2
and pin C2 on connector X42 (J3) to left front turn light Beacon Light
(E2), left rear turn light (E3), right front turn light (E4),
and right rear turn light (E5). The FLC also broadcasts The beacon light can be turned on and off with the
the flashers’ state (on or off) across CAN to the CMU. beacon light switch (S27) on the SSM. When the LED
The CMU will flash the turn indicators to match the is illuminated, the FLC applies power from pins H1 and
flashers. If the key switch is off when the 4-way flasher H2 on connector X40 (J1) to the beacon light (E15).
switch is turned on, the FLC will turn on to power the Ignition power for the beacon light is supplied to the
flashers. FLC at pins H3 and H4 on connector X40 (J3).

092005
PN=467
T193256 –19–25NOV03

092005
PN=468
9015B-15-24 - A 9015B-15-24 - B
T193256 –19–2
TM2075 (03
9015B-15-24 - A
–19–25NOV03

092005
PN=468
9015B-15-24 - B
Air Conditioning arm reaches the park position. The front wiper motor
park signal receives ignition power from the front wiper
The air conditioning system can be enabled using the motor 10 A fuse (F56). When the wipers are turned off,
A/C (on/off) switch (S22) on the SSM. Before the FLC the FLC supplies power to the motor until the park
will energize the A/C compressor clutch, it must signal is received.
receive power at pin D1 of connector X40 (J1),
verifying that the blower motor and pressurizer motor Front Washer Pump
are turned on. Once the FLC receives power at pin D1
and the A/C (on/off) switch is turned on (LED To activate the front washer pump (M2), the front
illuminated), the FLC will apply power from pin E3 on washer switch (S43) must be held down on the SSM.
connector X42 (J3). Ignition power for the A/C The FLC will apply power from pin D1 on connector
compressor clutch is supplied to the FLC at pins H3 X42 (J3) to activate the front washer pump. Ignition
and H4 on connector X42 (J3). This will energize the power for the front washer pump is supplied to the
A/C compressor clutch when the freeze control switch FLC at pins G1 and G2 on connector X42 (J3). The
(B35) and A/C binary pressure switch (B50) are FLC will cycle the front wiper at low speed three times
closed. The freeze control switch will open if the after the release of the front washer switch.
system begins to freeze and the A/C binary pressure
switch will open if the pressures are out of operating Rear Wiper
range. The A/C compressor clutch 1 A diode (V11)
suppresses voltage spikes created from the clutch The rear wiper switch (S20) on the SSM has four
energizing and de-energizing. modes: off, intermittent, low speed, and high speed.
When the left LED is illuminated, the FLC applies 9015B
Front Wiper power from pins D3 and D4 of connector X40 (J1) to 15
25
rear wiper motor low speed input at an intermittent
The front wiper switch (S43) on the SSM has four rate. Ignition power for the low speed motor input is
modes: off, intermittent, low speed, and high speed. supplied to the FLC at pins G3 and G4 on connector
When the left LED is illuminated, the FLC applies X40 (J1). When the left and center LEDs are
power from pins E3 and E4 of connector X40 (J1) to illuminated, the FLC functions the same as in
front wiper motor low speed input at an intermittent intermittent mode, except the output is constant. When
rate. Ignition power for the low speed motor input is all three LEDs are illuminated, the FLC applies power
supplied to the FLC at pins G3 and G4 on connector from pin A1 of connector X42 (J3) to the rear wiper
X40 (J1). When the left and center LEDs are motor high speed input and wiper motor operates at
illuminated, the FLC functions the same as in high speed. Ignition power for the high speed motor
intermittent mode, except the output is constant. When input is supplied to the FLC at pins G1 and G2 on
all three LEDs are illuminated, the FLC applies power connector X42 (J3).
from pin C1 of connector X42 (J3) to the front wiper
motor high speed input and wiper motor operates at The FLC receives a park position signal from the wiper
high speed. Ignition power for the high speed motor motor at pin E1 on connector X41 (J2) when the wiper
input is supplied to the FLC at pins G1 and G2 on arm reaches the park position. The rear wiper motor
connector X42 (J3). park signal receives ignition power from rear wiper
motor 10 A fuse (F55).When the wipers are turned off,
The FLC receives a park position signal from the wiper the FLC supplies power to the motor until the park
motor at pin E2 on connector X41 (J2) when the wiper signal is received.

092005
PN=469
Rear Washer Pump X42 (J3) to activate the rear washer pump. Ignition
power for the rear washer pump is supplied to the FLC
To activate the rear washer pump (M4), the rear at pins G1 and G2 on connector X42 (J3). If the rear
washer switch (S44) must be held down on the SSM. wiper is not active at the time of button press, the FLC
The FLC will apply power from pin C1 on connector will cycle the rear wiper at low speed five times.
OUT1738,0000149 –19–02FEB05–18/18
9015B
15
26

092005
PN=470
Transmission Control Unit (TCU) Circuit Theory of Operation (S.N. 590068— )

T193429 –19–10NOV03
OUT1738,000014A –19–30NOV04–1/5

092005
PN=471
9015B-15-27 - A 9015B-15-27 - B 9015B-15-27 - C
Transmission Control Unit (TCU) Circuit Theory of Operation (S.N. 590068— )

T193429 –19–10NOV03
OUT1738,000014A –19–
TM2075 (03MAR05) 9015B-15-27 644J and 72
9015B-15-27 - A
A –19–30NOV04–1/5
nd 724J Loader
092005
PN=471
9015B-15-27 - B
9015B-15-27 - C
9015B-15-27 - Blank
The Transmission Control Unit (TCU) (A3) monitors applied to TCU pins 4 and 62, is used to compute the
gear speeds at several points in the transmission and ground speed of the machine. For more information on
controls the transmission control valve according to the these sensors, see Electrical Component
monitored speeds and operator input. The TCU also Specifications (S.N. 590068— ). (Group 9015B-20.)
controls the neutral start, park brake, and back-up
alarm functions. When the transmission is in automatic mode and either
second, third, or fourth gear is selected, the TCU will
Battery power is supplied to the TCU through the TCU start machine travel in second gear, unless the auto to
battery power 10 A fuse (F18) to TCU pins 23 and 68. 1st option is enabled in the CAN Monitor Unit (CMU).
Ignition power is supplied through the TCU ignition See CAN Monitor Unit (CMU) Circuit Theory of
power 5 A fuse (F28) to TCU pin 45. Operation (S.N. 590068— ). (Group 9015B-15.)
When the engine is started, the TCU keeps the When the quick shift switch (S7) is pressed, power
transmission in neutral, regardless of shifter position. If from the restriction switch/radio ignition power 10 A
the shifter is not in neutral, the TCU requires the fuse (F11) is applied to TCU pin 44. If the transmission
shifter be placed in neutral first before forward or is in manual mode, the TCU will shift the transmission
reverse can be selected. down one gear. A second press of the switch will
either shift the transmission down another gear or back
The shifter is available as the joystick gear select (S9) to the original gear, depending on the selected mode
or the steering column shifter switch (S10). in the CMU. See CAN Monitor Unit (CMU) Circuit
Theory of Operation (S.N. 590068— ) for more
9015B Each shifter is supplied ignition power through the information. (Group 9015B-15.)
15 TCU ignition power 5 A fuse (F28). The shifter will
28
then supply power to the appropriate pins on the TCU The TCU controls the transmission’s gear selection by
to identify the selected gear range and gear. The controlling the six proportional solenoids in the
operation mode (manual or automatic) is controlled by transmission control valve. The TCU modulates the
the automatic transmission switch (S6) on the sealed current supplied to the solenoid to control the
switch module (SSM) (A6). For more information on smoothness of the clutch pack engagement.
the SSM, see Flex Load Controller (FLC) Circuit
Theory of Operation (S.N. 590068— ). (9015B-15.) • Transmission control solenoid 1 (Y1) controls the
high-range forward clutch pack (K4)
The TCU has four inductive-type speed sensors • Transmission control solenoid 2 (Y2) controls the
located at various places in the transmission. The reverse clutch pack (KR)
torque convertor input speed sensor (B28) applies a • Transmission control solenoid 3 (Y3) controls the
pulsed signal at TCU pins 3 and 19 from which the first speed clutch pack (K1)
TCU can calculate the engine speed at the torque • Transmission control solenoid 4 (Y4) controls the
convertor output. The torque convertor output speed third speed clutch pack (K3)
sensor (B29) applies a pulsed signal at TCU pins 3 • Transmission control solenoid 5 (Y5) controls the
and 41 from which the TCU can calculate the output low-range forward clutch pack (KV)
speed at the torque convertor. The internal clutch • Transmission control solenoid 6 (Y6) controls the
speed sensor (B30) applies a pulsed signal at TCU second speed clutch pack (K2)
pins 3 and 42 from which the TCU can calculate the
clutch pack speed. The transmission output shaft For more information on the clutch pack operation, see
speed sensor (B31) is supplied power from the Transmission Clutch Engagement and Solenoids
transmission output speed sensor 5 A fuse (F40) and Activated. (Group 9020-05.)
monitors the output shaft speed. The signal, which is
Continued on next page OUT1738,000014A –19–30NOV04–2/5

092005
PN=472
The transmission oil temperature sensor (B32) is a of 300 rpm input signal before it will allow the release
variable resistance temperature sensor. The resistance of the park brake. The data from the torque converter
is sensed at TCU pins 39 and 46. The TCU input speed sensor (B28) can be viewed in the
broadcasts the transmission oil temperature across diagnostic menu of the CMU.
CAN to the flex load controller (FLC) and the CMU.
The FLC uses the transmission oil temperature for the To release the park brake press and hold the park
proportional fan drive speed calculation. The CMU brake release switch (S8) in the momentary or OFF
displays the transmission oil temperature on the position. Ignition power flows across the park brake
gauge. release switch/back-up alarm 5 A fuse (F32) and
across the park brake release switch (S8) to pins 21
The transmission oil filter restriction switch (B20) is a and 31 of the TCU connector X23. When the TCU
normally open switch that is closed by filter bypass oil detects power on these two pins, the TCU applies a
pressure. When the filter becomes clogged, the bypass ground on pin 33 of connector X23 to energize the
valve opens oil pressure increases at the switch. The park brake release solenoid (Y19). With the solenoid
TCU broadcasts the switch state across CAN to the energized transmission oil begins flowing through the
CMU, which will illuminate the indicator if a restriction park brake solenoid valve to the park brake.
occurs.
The transmission oil used to release the park brake
Park Brake Operation must also open the park brake pressure switch (B34).
This switch must open immediately after the park
The park brake is a spring applied, hydraulically brake release solenoid (Y19) has been energized. This
released device. The park brake operation is controlled confirms to the TCU that adequate oil pressure is 9015B
by the TCU. The park brake circuit consists of the park present to release the park brake. 15
29
brake release switch (S8), park brake pressure switch
(B34), and park brake release solenoid (Y19). Once the TCU determines the park brake has been
released (park brake release solenoid (Y19) is
The park brake release switch (S8) is a three position energized and the park brake pressure switch (B34) is
switch. The ON and center positions are detented. The open), power is removed from pin 30 of TCU
OFF position is a momentary position. It has springs to connector X23. The park brake status is broadcast
return the switch to the center position. The park brake across CAN to the CMU and the park brake light is
release switch (S8) receives ignition power from the turned off. When the park brake light goes out the park
park brake release switch/back up alarm 5 A fuse brake pressure release switch (S8) can be released.
(F32). The switch returns to its center position with power
applied to only pin 21 of the TCU connector X23. The
The park brake pressure switch (B34) is a normally transmission can then be shifted into gear.
closed switch. It is closed when the transmission oil
pressure is low. In the closed position power is If the park brake pressure switch (B34) is slow to open
supplied to pin 30 of connector X23. This illuminates or does not open, the TCU will lift the ground at pin 33
the park brake light on the CMU of the TCU connector X23 and de-energize the park
brake release solenoid (Y19).
Before the park brake can be released the key switch
(S1) must be ON and the engine running. The TCU The apply the park brake turn the key switch (S1) to
receives the RPM signal from the torque converter the OFF position or place the park brake release
input speed senor (B28) on pin 19 of the TCU switch (S8) in the ON position.
connector X23. The TCU software requires a minimum

092005
PN=473
In the event the engine should fail while the machine is The clutch cut-off function has four settings: off, level
being operated, the park brake may not set slope, small slope, and steep slope. With no LED’s
immediately. If the engine would stop running but the illuminated the clutch cut-off feature is off. With one
key switch (S1) remains in the ON position, the park LED illuminated clutch cut-off is set in level ground
brake release solenoid (Y19) will remain energized. mode. With two LED’s illuminated clutch cut-off is set
The TCU software receives a data input from the at small slope mode. When all three LED’s are
torque converter input speed sensor of 50 rpm or less, illuminated clutch cut-off is set at steep slope mode.
the software considers the engine not to be running. Regardless of which clutch cut-off setting is selected
The TCU software will look next at the data from the when set point to release the clutch is reached the
transmission output speed sensor (B31) for ground TCU will demodulate only the solenoids of the
speed. If the machine is moving at a ground speed of directional clutch packs to place the transmission in
approximately 1/2 mph or less, the TCU software will neutral.
lift the ground at pin 33 of the TCU connector X23 and
de-energize the park brake release solenoid (Y19). The TCU software has programmed voltage thresholds
to release and apply the directional clutch pack
Back-Up Alarm associated the three settings. In the level ground
setting (1 LED light), for example, either brake pedal
The back-up alarm (H3) receives ignition power from only needs to be pressed down slightly to reach the
the park brake release switch/back-up alarm 5 A fuse release point. As the settings increase from level
(F32). When the reverse gear range is selected, the ground to steep slope, the service brake pedal must
TCU will apply ground from TCU pin 7 to the alarm , be pressed further before the release point is reached.
9015B causing it to sound. In small slope (2 LED lights) the service brake pedal
15 must be pressed about halfway down for the TCU to
30
Clutch Cut-Off place the transmission in neutral. When all three LEDs
are illuminated, the service brake pedal needs to be
The clutch cut-off sensor (B33) supplies the TCU with pressed almost all of the way down to reach clutch
a variable resistance based on brake pedal position. cut-off.
The clutch cut-off sensor (B33) receives power from
pin 37 of TCU connector X23. The TCU senses The use of the service brake pedal to operate the
changes in resistance at pins 24 and 38 of X23 clutch cut-off feature also applies the service brakes.
connector.
Level Ground Set Point to Release Voltage 1.20

Clutch
Level Ground Set Point to Apply Voltage 1.18

Clutch
Small Slope Set Point to Release Voltage 1.64

Clutch
Small Slope Set Point to Apply Voltage 1.60

Clutch

092005
PN=474
Steep Slope Set Point to Release Voltage 2.00

Clutch
Steep Slope Set Point to Apply Voltage 1.94

Clutch
Voltage for the Clutch Cut-Off Sensor (B33) can be

viewed in the Diagnostics / Transmission (3-3) CMU
menu.
OUT1738,000014A –19–30NOV04–5/5
9015B
15
31

092005
PN=475
CAN Monitor Unit (CMU) Circuit Theory of Operation (S.N. 590068— )
9015B
15
32
–19–10NOV03
T193467
Continued on next page OUT1738,000014B –19–18JUN03–1/33

092005
PN=476
The CAN Monitor Unit (CMU) receives battery power The center of the CMU is a liquid crystal display (LCD)
from the CMU battery power 5 A fuse (F34). The turn which shows a plethora of machine information. The
switch (S25) and the CMU receive ignition power from home screen contains gear selection, transmission
the CMU/SSM ignition power 5 A fuse (F13). When a mode, engine speed, odometer, hourmeter, and
left or right turn is selected, the turn switch applies speedometer information. To cycle between odometer,
ignition power to the appropriate CMU pin. The CMU hourmeter, and speedometer, press the NEXT button.
broadcasts the turn signal status across CAN to the
flex load controller (FLC). The FLC broadcasts the The CMU has a menu-based information structure. To
output flasher state (on or off) to the CMU. The CMU reach the main menu, press the MENU button. Press
receives this signal and flashes the turn indicators to BACK to go back one screen, press NEXT to scroll
match the flashers. If the 4-way flashers are active down the menu, and press SELECT to select the
when the turn switch is used, the direction chosen on highlighted item. Selecting an item on the main menu
the switch will continue to flash while the other side will will bring up the appropriate submenu. Each submenu
illuminate solid until the turn switch is returned to in this referenced with a two number reference (X-X).
neutral. The first number references the main menu item
number and the second number references the
The fuel level sensor (B17) is a float arm type sensor. submenu item number. These instructions will work for
As the fuel level falls, the float arm moves with the fuel all submenus unless noted.
level and turns a potentiometer. The resistance is
sensed by the CMU at pins F and N. The CMU then The service menu allows access to addition items not
converts this resistance into a gauge position. available in the normal menu system. These items are
marked with a footnote. To enter the service menu, 9015B
With the key switch in the off position, the SELECT press the MENU button and hold it down for 5 15
33
button can be pressed to “wake up” the monitor. As seconds.
long as the SELECT button is pressed, the monitor will
display machine hours, battery voltage, and fuel level.
OUT1738,000014B –19–18JUN03–2/33
CMU Main Menu

Main Menu 1/5
1. Codes (1)
2. Machine Settings (2) 1-Codes
3. Diagnostics (3) 2-Machine Settings
4. Monitor Settings (4)
3-Diagnostics
–19–10NOV03
5. Machine Config1 (5)

4-Monitor Settings
5-Machine Config
T196107
1
Only Available in the Service Menu

092005
PN=477
Codes (1)
Codes 1/3
1-Active Codes
2-Stored Codes
–19–10NOV03
3-Clear Codes
T196108
OUT1738,000014B –19–18JUN03–4/33
1. Active Codes (1-1)

This menu displays the Diagnostic Trouble Codes
(DTCs) that are currently active on the machine. A
detailed description of the code, the source controller
Active Codes 1/3
(the controller which is reporting a problem), and the Right Turn Lts
SPN.FMI number. Press NEXT to display the next
High Current
–19–30SEP03
code or BACK to get to (1). Press SELECT to view
9015B
more information about the DTC. The next screen will
15
show information on what to check to fix the code. FLC 2370.6
34
T193355
Active Codes 2/3
Fuse: F18 F28
Wires: M12 YEL M13 GRN
P18 RED P28 RED
–19–07NOV03
CONN PIN: X23 25
X23 26 23 68 45
T195057
SECTION: SE23

092005
PN=478
2. Stored Codes (1-2)

This menu displays the DTCs that are stored in
memory. A detailed description of the code, the source
controller (the controller which is reporting a problem),
Stored Codes 2/3
and the SPN.FMI number. Press NEXT to display the CAN Comm
next code or BACK to get to (1). Press SELECT to
Lost for TCU
–19–08OCT03
view more information about the DTC. The next screen
will show the number of occurrences, when the code
first and last appeared and the sensor reading at that CMU 2003.9
time. Press SELECT to view information on what to
T193356
check to fix the code.
3. Clear Codes1 (1-3)
This menu will clear all stored DTCs on the machine.
Press SELECT to clear the codes or BACK to get back
to (1).
Stored Codes 2/3
Occurrences: 7
–19–23SEP03
First: Last:
118.0 hrs 119.5 hrs 9015B
15
T195058
35
Stored Codes 2/3

Fuse: F18 F28
Wires: M12 YEL M13 GRN
P18 RED P28 RED
–19–30SEP03
CONN PIN: X23 25
X23 26 23 68 45
T195059
SECTION: SE23
1
OUT1738,000014B –19–18JUN03–6/33
Machine Settings (2)
Machine Settings 1/4

1-Quick Shift
2-Auto to 1st
–19–06OCT03
3-Job Timer
4-Stopwatch
T193357

092005
PN=479
1. Quick Shift (2-1)

This menu sets the mode for the quick shift switch
(S7). Press SELECT to select the desired mode.
• Down/Up—The transmission will shift down one gear
Quick Shift 1/2
with one push then shift up one gear with a second Down/Up
push.
–19–05AUG03
• Down Only—The transmission will shift down one Down Only
gear with each push.
T193358
OUT1738,000014B –19–18JUN03–8/33
2. Auto to 1st (2-2)

This menu sets what gear the transmission will start in
when Automatic mode is selected. Press SELECT to
select the desired mode.
Auto to 1st 1/2
• Off—The transmission will start out in second gear Off
when automatic mode is selected.
–19–05AUG03
• On—The transmission will start out in first gear when On
9015B
automatic mode is selected.
15
36
T193359
OUT1738,000014B –19–18JUN03–9/33
3. Job Timer (2-3)

This menu controls a continually running job timer.
Press SELECT reset the job timer or press BACK to
get back to (2).
Job Timer
SELECT to Reset
–19–05AUG03
BACK to Exit
0.0 hours
T193360
OUT1738,000014B –19–18JUN03–10/33
4. Stop Watch (2-4)

This menu controls a stop watch. Press SELECT to
start and stop the stop watch. Press NEXT to reset the
stopwatch or press BACK to get back to (2).
STOPWATCH
SELECT on/off
NEXT to reset
–19–30SEP03
BACK to Exit
00:00:00.0
T193361

092005
PN=480
Diagnostics (3)
Diagnostics 1/8
1-Battery Monitor
2-Engine Sensors
3-Transmission
4-Hydraulic
5-Machine
–19–30SEP03
6-Machine Switches
7-Switch Module
T193362
8-Machine I.D.
OUT1738,000014B –19–18JUN03–12/33
9015B
1. Battery Monitors (3-1) 15
This menu displays the voltage level of both batteries. 37
Press BACK to get back to (3). Battery Monitor
NOTE: If 12 volt center tap wire is not connected to the Left Battery
right battery, left battery will display system 13.7
–19–05AUG03
voltage and right battery will display 0.0.
Right Battery
13.7
T193363

092005
PN=481
2. Engine Sensors (3-2)

This menu shows the current readings of the sensors Engine Sensors 1/6
which are monitoring the engine. 1-Display All
• Display All—All of the engine sensors will be
displayed. 2-Coolant Temp
• Coolant Temp—The engine coolant temperature as
measured by the engine coolant temperature sensor
3-Oil Pressure
(B1) is displayed. 4-Throttle Sensor
• Oil Pressure—The oil pressure as measured by the
5-MAT
–19–10NOV03
engine oil pressure sensor (B23) is displayed.
• Throttle Sensor—The throttle percentage as 6-Fuel Temp
measured by the analog throttle position sensor
(B14) is displayed.
T196109
• MAT—The manifold air temperature as measured by
the manifold air temperature sensor (B7) is
displayed.
• Fuel Temp—The fuel temperature as measured by
the fuel temperature sensor (B5) is displayed.
9015B
15
38
OUT1738,000014B –19–18JUN03–14/33
3. Transmission (3-3)
This menu shows the current readings of the sensors Transmission 1/7
which are monitoring the transmission. 1-Display All
• Display All—All of the transmission sensors will be
displayed. 2-Oil Temp
• Oil Temp—The transmission oil temperature as
measured by the transmission oil temperature sensor
3-TC Input Speed
(B32) is displayed. 4-TC Output Speed
• TC Input Speed—The torque converter input speed
5-Clutch Speed
–19–01OCT03
(engine speed) as measured by the torque converter
input speed sensor (B28) is displayed. 6-Output Shaft Spd
• TC Output Speed—The torque converter output
speed as measured by the torque converter output 7-Clutch Cutoff V
T193372
speed sensor (B29) is displayed.

• Clutch Speed—The clutch speed as measured by
internal clutch speed sensor (B30) is displayed.
• Output Shaft Spd—The output shaft speed sensor as
measured by the transmission output speed sensor
(B31) is displayed.
• Clutch Cutoff V—The clutch cut-off sensor voltage as
measured by the clutch cut-off sensor (B33) is
displayed.

092005
PN=482
4. Hydraulic (3-4)
This menu shows the current readings of the sensors
which are monitoring the hydraulic system.
• Display All—All of the hydraulic sensors will be
Hydraulic 1/3
displayed. 1-Display All
• Oil Temp—The hydraulic oil temperature as
2-Oil Temp
–19–25JUL03
measured by the hydraulic oil temperature sensor
(B15) is displayed. 3-Hyd Sys Press
• Hyd Sys Press—The hydraulic system pressure as
measured by the hydraulic system pressure (B8) is
T193379
displayed.
OUT1738,000014B –19–18JUN03–16/33
9015B
5. Machine (3-5) 15
This menu shows the current readings of various Machine 1/4 39
sensors on the machine.
• Display All—All of the sensors will be displayed.
1-Display All
• Boom Height—The boom height is displayed as the 2-Boom Height
percentage of the total boom travel as measured by
3-Bucket Position
–19–04NOV03
the analog BHKO/RTC position sensor (B45).
• Bucket Position—The bucket position is displayed as 4-Fuel Level
the percentage of the total bucket travel as
measured by the analog RTD position sensor (B37).
T193382
• Fuel Level—The fuel level is displayed as the
percentage of the full tank as measured by the fuel
level sensor (B17).

092005
PN=483
6. Machine Switches (3-6)

These four screens show the state (on/off) of the
switches on the machine. Machine Switches 1/4
• Hyd Oil Filt Res—The state of the hydraulic filter Off Hyd Oil Filt Res
restriction switch (B21) is displayed.
• Brake Accum Chg—The state of the service brake Off Brake Accum Chg
accumulator charge pressure switch (B27) is
displayed. Off Steering Press
• Steering Press—The state of steering system
pressure switch (B25) is displayed.
• Brake Light—The state of the brake light pressure
switch (B40) is displayed.
• Ret to Dig Bkt—The state of the return-to-dig switch
(S17) is displayed. Machine Switches 2/4
• Start Signal—The state of the key switch (S1) start Off Brake Light
position is displayed.
• 4 Way Flashers—The state of the 4-way flasher Off Ret to Dig Bkt
switch (S24) is displayed.
• Blower—The state of the blower motor (M6) is Off Start Signal
displayed.
• Front Wiper Park—The state of the front wiper motor
9015B (M3) internal park switch is displayed.
15 • Rear Wiper Park—The state of the rear wiper motor
40
(M5) internal park switch is displayed.
Machine Switches 3/4
Off 4 Way Flashers
Off Blower
Off Front Wiper Park
Machine Switches 4/4

Off Rear Wiper Park
–19–15OCT03
T193385

092005
PN=484
7. Switch Module (3-7)

This menu tests the momentary switches in the sealed
switch module (SSM). When you press the switch, the
matching square on the monitor display will darken if
SSM
the switch is working properly. Test
–19–22SEP03
Press
any
Button..
T193389
OUT1738,000014B –19–18JUN03–19/33
8. Machine I.D. (3-8)

This menu displays the serial numbers, part numbers,
software numbers, and software numbers for various Machine ID 1/5
devices on the machine. 1-CMU
• CMU—The serial number, part number, software
number, and software version are displayed for the 2-FLC
–19–01OCT03
CAN Monitor Unit (CMU) (H2). 3-SSM 9015B
• FLC—The serial number, part number, software
15
number, and software version are displayed for the 4-TCU 41
flex load controller (FLC) (A2).
5-Serial #
T193390
• SSM—The part number, software number, and
software version are displayed for the sealed switch
module (SSM) (A4).
• TCU—The machine model number, machine serial
number, TCU part number, and software version are
displayed for the transmission control unit (TCU)
(A3).
• Serial #—The serial number of the machine is
displayed.
OUT1738,000014B –19–18JUN03–20/33
Monitor Settings (4)

Monitor Settings 1/5
1-Units
2-Backlighting
–19–10NOV03
3-LCD Contrast
4-Hide Main Menu
5-Language
T196111

092005
PN=485
1. Units (4-1)
This menu sets the units for all functions of the CMU.
Press SELECT to select the desired mode.
• English—All units will be English standard units.
Units 1/2
• Metric—All units will be metric units. English
–19–05AUG03
Metric
T193395
OUT1738,000014B –19–18JUN03–22/33
2. Hide Main Menu (4-2)

This menu sets the display mode for the main menu.
Press SELECT to select the desired mode.
• Hide Main Menu—The main menu will not be
Hide Main Menu 1/2
available. The service menu will have to be entered Hide Main Menu
to access any menus.
–19–05AUG03
• Show Main Menu—The main menu will be available Show Main Menu
9015B
when the MENU button is pressed.
15
42
T193396
OUT1738,000014B –19–18JUN03–23/33
3. Backlighting (4-3)
This menu sets the amount of backlighting for the
CMU. The backlighting can be adjusted in increments
of 1 from 0 (no light) to 10 (brightest). Press BACK to
Backlighting
decrement the value, press NEXT to increment the BACK to decrease
value, and press SELECT to store the current value.
NEXT to increase
–19–15OCT03
Once SELECT is pressed, the CMU will confirm that
the value is stored. To exit this menu, press MENU to
return to the main menu. SELECT to store
10
T193397
OUT1738,000014B –19–18JUN03–24/33
4. LCD Contrast (4-4)

This menu sets the amount of contrast for the CMU
LCD. The contrast can be adjusted in increments of 1
from 1 (lightest) to 10 (darkest). Press BACK to
LCD Contrast
decrement the value, press NEXT to increment the BACK to decrease
NEXT to increase
–19–22SEP03
Once SELECT is pressed, the CMU will confirm that

the value is stored. To exit this menu, press MENU to
return to the main menu. SELECT to store
9
T193398

092005
PN=486
5. Language1 (4-5)
This menu sets the language for all functions of the
CMU. Press SELECT to select the desired language.
• English—The menu language will be set to English. Language 1/3
• Spanish—The menu language will be set to Spanish. English
• French—The menu language will be set to French.
–19–01OCT03
Spanish
French
T194687
1
OUT1738,000014B –19–18JUN03–26/33
Machine Config (5)1

Machine Config 1/5
1-Machine Model
2-Tire Size
3-Enable Options
–19–17SEP03
4-Set Altitude 9015B
15
5-Trans Clutch Cal 43
T194688
1
6-Fan Speed %
OUT1738,000014B –19–18JUN03–27/33
1. Machine Model (5-1)

This menu sets the machine model for the CMU menu
system. Press SELECT to select the machine model.
Machine Model 1/8
• 444—The machine model will set to 444. 444
• 544—The machine model will set to 544.
644
744
824
–19–18SEP03
844
T194689

092005
PN=487
2. Tire Size (5-2)

This menu sets the tire size for the machine. Press
Tire Sizes 1/11
SELECT to select the tire size. The CMU will confirm 17.5
the change.
• 17.5—The tire size will be set to 17.5. 600/65
• 600/65—The tire size will be set to 600/65.
• 20.5—The tire size will be set to 20.5. 20.5
• 23.1—The tire size will be set to 23.1.
650/65
• 23.5—The tire size will be set to 23.5. 23.1
• 28L—The tire size will be set to 28L. 23.5
• 800/65—The tire size will be set to 800/65. 750/65
28 L
–19–10NOV03
26.5
800/65
T194690
29.5
9015B
15
44

092005
PN=488
3. Enable Options (5-3)

This menu enables and disables machine options. Enable Options 1/9
NOTE: If the machine is equipped with a certain option, Work Lights
the option must be enabled in this menu for it to
function. AC
• Work Lights—The front and rear work lights will be
Engine Heaters
enabled or disabled. Ride Control
• AC—Air conditioning will be enabled or disabled.
• Engine Heaters—The engine air heaters will be Fan Drive
enabled or disabled.
• Ride Control—Ride Control will be enabled or Reverse Fan
disabled.
• Fan Drive—The proportional fan drive will be
Spin Control
enabled or disabled. Beacon
• Reverse Fan—The reverse fan drive will be enabled
or disabled. Dock Lights
• Spin Control—Spin Control will be enabled or
disabled. Pin Disconnect
• Beacon—The rotary beacon light will be enabled or
–19–13NOV03
disabled.
Axle Disconnect 9015B
• Dock Lights—The docking lights will be enabled or Sec. Steering 15
45
disabled.
Canopy
T196336
• More Options
• Pin Disconnect—The tool carrier pin disconnect
feature will be enabled or disabled.
• Axle Disconnect—The axle disconnect feature will be
• Sec. Steering—The secondary steering system will
be enabled or disabled.
• Canopy—The wiper and washer systems will be
OUT1738,000014B –19–18JUN03–30/33
4. Set Altitude (5-4)

This menu will change the low idle engine speed for
high altitude applications.
• Off—The ECU sets low idle at 900 rpm.
Set Altitude 1/3
• On—The ECU sets low idle at 1100 rpm. Off
On
–19–17SEP03
T194692

092005
PN=489
5. Trans Clutch Cal (5-5)

This menu performs the transmission clutch calibration
procedure. Before the procedure can be started, the
following conditions must be satisfied:
Trans Clutch Cal
• Shifter in Neutral Warning Proceeding will Calibrate
• Park Brake Applied Transmission
–19–17SEP03
• Engine Running and Below 1100 rpm
• Transmission Oil Temperature at 77°C (170°F)
Press Select to START
Press SELECT to start the procedure. The CMU
T194693
broadcasts the request across CAN to the TCU and
the TCU will initiate the procedure. If any errors occur
during the procedure, they will be displayed on the
CMU. Once the procedure is completed, the CMU will
require the key switch to be cycled to off, then the
engine restarted.
For more information on this procedure, see

Transmission Control Unit (TCU)—Electronic Clutch
Calibration (S.N. 590068— ). (Group 9020-20.)
9015B
15
46
OUT1738,000014B –19–18JUN03–32/33
6. Fan Speed % (5-6)

This menu temporarily sets the proportional fan speed.
The fan speed can be adjusted in increments of 10
from 0% (stopped) to 100% (full speed). Press BACK
Fan Speed %
to decrement the value, press NEXT to increment the BACK to decrease
NEXT to increse
–19–17SEP03
Once SELECT is pressed, the fan will operate at the
percentage selected until the key switch is cycled. To
exit this menu, press MENU to return to the main SELECT to store
menu. 90
T194694
OUT1738,000014B –19–18JUN03–33/33

092005
PN=490
Group 20
References
Diagnostic Trouble Codes Quick Reference List (S.N. 590068— )
The diagnostic trouble code number is indicated by an • 611.04—Injector Wiring Short Too Ground
(SPN) Suspect Parameter Number and a (FMI) Failure • 620.03—Sensor Supply Voltage Too High
Mode Indicator number. (91.03) 91 is the SPN number • 620.04—Sensor Supply Voltage Too Low
and 03 is the FMI number. • 627.01—Battery Supply Voltage Is Low
• 629.13—ECU Not Programed
Use SERVICE ADVISOR™ system or see Stored • 636.02—Engine Position Sensor
Codes in the Display Menu to view stored diagnostic • 636.08—Engine Position Sensor
trouble codes. • 636.10—Engine Position Sensor
• 637.02—Crank Position Input Noise
Engine Control Unit (ECU) Diagnostic Trouble • 637.07—Crank Position/Pump Position timing
Codes Moderately out of Sync
• 637.08—Crank Position Input Missing
NOTE: For more information See Engine Control Unit • 637.10—Crank Position Input Pattern Error
(ECU) Diagnostic Trouble Codes (S.N. • 639.13— CAN Bus Error
590068— ) • 651.05—Cylinder #1 Injector
• 651.06—Cylinder #1 Injector
• 91.09—Engine Throttle Input Invalid • 651.07—Cylinder #1 Injector
• 94.03—Fuel Pressure Short To Power • 652.05—Cylinder #2 Injector
• 94.04—Fuel Pressure Short To Ground • 652.06—Cylinder #2 Injector
• 94.10—Fuel Pressure To Low • 652.07—Cylinder #2 Injector 9015B
• 94.17—Fuel Rail Pressure Not Developed • 653.05—Cylinder #3 Injector 20
1
• 97.03—Water in Fuel Signal Voltage High • 653.06—Cylinder #3 Injector
• 97.04—Water in Fuel Signal Voltage Low • 653.07—Cylinder #3 Injector
• 97.16—Water in Fuel Detected • 654.05—Cylinder #4 Injector
• 105.03— Manifold Air Temperature Short To • 654.06—Cylinder #4 Injector
Power/Voltage Above Normal • 654.07—Cylinder #4 Injector
• 105.04— Manifold Air Temperature Short To • 655.05—Cylinder #5 Injector
Ground/Voltage Below Normal • 655.06—Cylinder #5 Injector
• 105.16— Manifold Air Temperature Too High • 655.07—Cylinder #5 Injector
• 110.00— Engine Coolant Temperature Too High • 656.05—Cylinder #6 Injector
(Most Severe) • 656.06—Cylinder #6 Injector
• 110.03— Engine Coolant Temperature Voltage • 656.07—Cylinder #6 Injector
Above Normal • 1080-03 —Sensor Supply Voltage Too High
• 110.04— Engine Coolant Temperature Voltage Short • 1080-04 —Sensor Supply Voltage Too Low
To Ground/Voltage Below Normal • 1347.05—Fuel Pump Solenoid 1 Open
• 110.16— Engine Coolant Temperature High • 1347.07—Fuel System Failure
(Moderately Severe) • 1347.10—Fuel Pump Solenoid 1 Flow Not Detected
• 158.17— ECU Can Not Power Down • 1348.05—Fuel Pump Solenoid 2 Open
• 174.03— Fuel Temperature Voltage Too High • 1348.10—Fuel Pump Solenoid 1 Flow Not Detected
• 174.04— Fuel Temperature Voltage Too Low • 1568.02—Troque Curve Invalid
• 174.16—Fuel Temperature High (Moderately • 1569.31—Engine Protection Derate
Severe)
• 611.03—Injector Wiring Short Too Power CAN Monitor Unit (CMU) Diagnostic Trouble Codes

092005
PN=491
References
NOTE: For more information See CAN Monitor Unit • 2362.06—Rear Work Lights Circuit High Current
(CMU) Diagnostic Trouble Codes (S.N. • 2362.05—Rear Work Lights Circuit Open
590068- ) • 2366.06—Docking Work Lights Circuit High Current
• 2366.05—Docking Work Lights Circuit Open
• 829.05—Fuel Level Sensor Open Or Short To • 2368.03—Left Turn Lights Circuit Short To Power
Power • 2368.05—Left Turn Lights Circuit Open
• 2000.09—Missing Message From ECU • 2368.06—Left Turn Lights Circuit High Current
• 2033.09—Missing Message From FLC • 2370.03—Right Turn Lights Circuit Short To Power
• 2003.09—Missing Message From TCU • 2370.05—Right Turn Lights Circuit Open
• 2140.09—Missing Message From SSM • 2370.06—Right Turn Lights Circuit High Current
• 2367.04—Left Turn Switch Shorted To Ground • 2378.03—Marker/Tail Lights Circuit Short To Power
• 2369.04—Right Turn Switch Shorted To Ground • 2378.05—Marker/Tail Lights Circuit Open
• 2378.06—Marker/Tail Lights Circuit High Current
Flex Load Controller (FLC) Diagnostic Trouble • 2386.06—E15 Beacon Light Circuit High Current
Codes • 2386.05—E15 Beacon Light Circuit Short To Power
• 2717.03—A4 Return-to-Dig Detent Coil Short To
NOTE: For more information See Flex Load Controller Power
(FLC) Diagnostic Trouble Codes (S.N. 590068- • 2717.06—A4 Return-to-Dig Detent Coil Short To
) Ground
• 2875.04—S24 Four Way Flasher Switch Short To
• 1045.04—Brake Light Pressure Switch Shorted To Ground
9015B Ground • 522438.03—Y20 Pin Disconnect Solenoid Short To
20 • 1071.31—Variable Speed Fan Circuit Power
2
• 117.01—Service Brake Accumulator Low • 522438.05—Y20 Pin Disconnect Solenoid Open
• 117.04—Service Brake Accumulator Short To • 522438.06—Y20 Pin Disconnect Solenoid High
Ground Current
• 1638.00—Hydraulic Oil Temperature High • 522437.04—S17 Return-to-Dig Sensor (Bucket)
• 1638.04—Hydraulic Oil Temperature Circuit Shorted Short To Ground
To Ground • 522436.04—S37 Return-to-Dig Sensor (Forks) Short
• 167.16—System Voltage High (Engine Running) To Ground
• 167.18—System Voltage Low (Engine Running) • 299261.02—Machine Configuration Error
• 168.16—System Voltage High (Engine Off) • 444.18—Battery Voltage Imbalance
• 168.18—System Voltage Low (Engine Off) • 523137.01—Steering Pressure Low
• 1713.01—Hydraulic Oil Filter Restricted • 523137.04—Steering System Pressure Switch Short
• 1762.03—Hydraulic System Pressure Sensor To Ground
Voltage High • 523214.05—No Power From VEC To FLC
• 1762.04—Hydraulic System Pressure Sensor • 523215.05—No Power From VEC To FLC
Voltage Low • 523216.05—No Power From VEC To FLC
• 2000.19—Missing Message From ECU • 523217.05—No Power From VEC To FLC
• 2003.19—Missing Message From TCU • 523218.05—No Power From VEC To FLC
• 2023.19—Missing Message From CMU • 523219.05—No Power From VEC To FLC
• 2140.19—Missing Message From SSM • 523436.17—FLC Internal Timer Failure
• 2350.05—Drive Light Circuit Open • 523577.03—M8 Secondary Steering Pump Short To
• 2350.06—Drive Light Circuit High Current Power
• 2356.06—Front Work Lights Circuit High Current • 523577.05—M8 Secondary Steering Pump Open
• 2356.05—Front Work Lights Circuit Open

092005
PN=492
References
• 523577.06—M8 Secondary Steering Pump High • 928.05—Y28 Axle Disconnect Solenoid Open Circuit
Current • 928.06—Y28 Axle Disconnect Solenoid High Current
• 523786.03—B45 Analog Boom Position Sensor • 977.03—Y38 Reverse Fan Solenoid Short To Power
Voltage To High • 977.05—Y38 Reverse Fan Solenoid Open Circuit
• 523786.04—B45 Analog Boom Position Sensor • 977.06—Y38 Reverse Fan Solenoid High Current
Voltage To Low • 1079.04—FLC Sensor Supply Voltage Short To
• 523948.03—Y18, Y34 Ride Control Solenoids Short Ground
To Power • 1080.04—FLC Sensor Supply Voltage Short To
• 523948.05—Y18, Y34 Ride Control Solenoids Open Ground
• 523948.06—Y18, Y34 Ride Control Solenoids High • 524265.19—Data Error
Current • 522431.2—Hardware Failure
• 522435.03—Front Wiper (High Speed) Short To
Power Sealed Switch Module (SSM) Unit Diagnostic
• 522435.05—Front Wiper (High Speed) Open Circuit Trouble Codes
• 522435.06—Front Wiper (High Speed) High Current
• 522434.00—Front Wiper (Low Speed) Stalled Motor NOTE: For more information See Sealed Switch
• 522434.03—Front Wiper (Low Speed) Short To Module (SSM) Unit Diagnostic Trouble Codes
Power (S.N. 590068- )
• 522434.05—Front Wiper (Low Speed) Open Circuit
• 522434.06—Front Wiper (Low Speed) High Current • 629.12—SSM Watchdog Time Out/Update Software
• 522427.04—Front Wiper (Park) Missing • 2033.09—Missing CAN Message From FLC
• 522797.03—Front Washer Pump Short To Power • 639.12—SSM CAN Hardware Failure 9015B
• 522797.05—Front Washer Pump Open Circuit • 639.19—SSM Lost CAN Communications 20
3
• 522797.06—Front Washer Pump High Current • 523523.10—Rear Wiper Keypad Stuck Or SSM
• 522426.04—Rear Wiper (Park) Signal Missing Failure
• 522432.03—Rear Wiper (High Speed) Short To • 523524.10—Front Wiper Keypad Stuck Or SSM
Power Failure
• 522432.05—Rear Wiper (High Speed) Open Circuit • 523525.10—Front Washer Keypad Stuck Or SSM
• 522432.06—Rear Wiper (High Speed) High Current Failure
• 522433.00—Rear Wiper Stalled Motor • 523526.10—Reverse Fan Keypad Stuck Or SSM
• 522433.05—Rear Wiper (Low Speed) Open Circuit Failure
• 522433.06—Rear Wiper (Low Speed) High Current • 523527.10—Pin Disconnect Keypad Stuck Or SSM
• 522796.03—Rear Washer Pump Short To Power Failure
• 522796.05—Rear Washer Pump Open Circuit • 523528.10—A/C Keypad Stuck Or SSM Failure
• 522796.06—Rear Washer Pump High Current • 523529.10—Work Lights Keypad Stuck Or SSM
• 785.03—Y14, Y15 Pilot Enable Solenoids Short To Failure
Power • 523530.10—Beacon Light Keypad Stuck Or SSM
• 785.05—Y14, Y15 Pilot Enable Solenoids Open Failure
Circuit • 523531.10—Axle Disconnect Keypad Stuck Or SSM
• 785.06—Y14, Y15 Pilot Enable Solenoids High Failure
Current • 523532.10—Spin Control Keypad Stuck Or SSM
• 880.03—Brake Lights Short To Power Failure
• 880.05—Brake Lights Open Circuit • 523533.10—Clutch Cut-Off Keypad Stuck Or SSM
• 880.06—Brake Lights High Current Failure
• 928.03—Y28 Axle Disconnect Solenoid Short To • 523534.10—Pilot Enable Keypad Stuck Or SSM
Power Failure

092005
PN=493
References
• 523535.10—Ride Control Keypad Stuck Or SSM • 522407.04—Clutch Cut-Off Sensor Open

Failure • 522406.03—Transmission Oil Temperature Sensor
• 523536.10—Auto Transmission Keypad Stuck Or Short To Power
SSM Failure • 522406.04—Transmission Oil Temperature Sensor
• 523537.10—Drive Lights Keypad Stuck Or SSM Short To Ground
Failure • 522405.03—Park Brake Sensor Short To Power
• 523538.10—Keypad Not Used • 522405.04—Park Brake Sensor Short To Ground
• 523607.10—Return-to-Dig Keypad Stuck Or SSM • 522404.03—B28 Torque Converter Input Speed
Failure Sensor Short To Power
• 523608.10—Boom Height Kickout Keypad Stuck Or • 522404.04—B28 Torque Converter Input Speed
SSM Failure Sensor Short To Ground
• 523609.10—Return-to-Carry Keypad Stuck Or SSM • 522404.12—B28 Torque Converter Input Speed
Failure Sensor Open
• 523610.10—Rear Washer Keypad Stuck Or SSM • 522403.03—B29 Torque Converter Output Speed
Failure Sensor Short To Power
• 522403.04—B29 Torque Converter Output Speed
Transmission Control Unit (TCU) Diagnostic Sensor Short To Ground
Trouble Codes • 522403.12—B29 Torque Converter Output Speed
Sensor Open
NOTE: For more information See Transmission • 522402.03—B30 Transmission Internal Clutch
Control Unit (TCU) Diagnostic Trouble Codes Speed Sensor Short To Power
9015B (S.N. 590068- ) • 522402.04—B30 Transmission Internal Clutch
20 Speed Sensor Short To Ground
4
• 522421.02—CAN Signal For Automatic Downshift Is • 522402.12—B30 Transmission Internal Clutch
Defective Speed Sensor Open
• 522420.02—CAN Signal For Manual Downshift Is • 522401.03—B31 Transmission Output Speed
Defective Sensor Short To Power
• 522419.02—CAN Signal For Clutch Cut-Off Is • 522401.04—B31 Transmission Output Speed
Defective Sensor Short To Ground
• 522418.02—Clutch K1 Calculated Value Is Out Of • 522401.12—B31 Transmission Output Speed
Range Sensor Open
• 522417.02—Clutch K2 Calculated Value Is Out Of • 522401.02—B31 Transmission Output Speed
Range Sensor Failed Signals
• 522416.02—Clutch K3 Calculated Value Is Out Of • 2023.09—CAN Communication Lost For CMU
Range • 2033.09—CAN Communication Lost For FLC
• 522415.02—Clutch K4 Calculated Value Is Out Of • 522399.03—Y1 Solenoid Short To Power
Range • 522399.04—Y1 Solenoid Short To Ground
• 522414.02—Clutch KV Calculated Value Is Out Of • 522398.05—Y1 Solenoid Open
Range • 522397.03—Y2 Solenoid Short To Power
• 522413.02—Clutch KR Calculated Value Is Out Of • 522396.04—Y2 Solenoid Short To Ground
Range • 522395.05—Y2 Solenoid Open
• 522412.12—Gear Selector Fault • 522394.03—Y3 Solenoid Short To Power
• 522411.12—FNR Selector Fault • 522393.04—Y3 Solenoid Short To Ground
• 522410.12—Engine Does Not Derate • 522392.05—Y3 Solenoid Open
• 522409.12—FNR Selector #2 Selector Fault • 522391.03—Y4 Solenoid Short To Power
• 522407.03—Clutch Cut-Off Sensor Short To Power • 522390.04—Y4 Solenoid Short To Ground

092005
PN=494
References
• 522389.05—Y4 Solenoid Open • 522374.04—TCU Supply Voltage Short To Ground

• 522388.03—Y5 Solenoid Short To Power • 522373.03—TCU Supply Voltage High
• 522387.04—Y5 Solenoid Short To Ground • 522372.04—TCU Supply Voltage Low
• 522386.05—Y5 Solenoid Open • 522371.02—TCU P78 Red Wire Shorted To Power
• 522385.03—Y6 Solenoid Short To Power Or Ground
• 522384.04—Y6 Solenoid Short To Ground • 522370.02—TCU P78 Red Wire Shorted To Power
• 522383.05—Y6 Solenoid Open Or Ground
• 522382.03—H3 Back-Up Alarm Short To Power • 522369.03—X1 Service ADVISOR System
• 522381.04—H3 Back-Up Alarm Short To Ground Connector Shorted To Power
• 522380.05—H3 Back-Up Alarm Open • 522369.04—X1 Service ADVISOR System
• 522379.03—Y19 Park Brake Release Solenoid Short Connector Shorted To Ground
To Power • 522368.02—TCU Memory Failure
• 522378.04—Y19 Park Brake Release Solenoid Short • 522367.13—TCU Configuration Lost
To Ground • 522366.13—TCU Application Error
• 522377.05—Y19 Park Brake Release Solenoid • 522365.13—TCU Limp Home Request
Open • 522364.07—Transmission Clutch Adjustment Out Of
• 522376.0—Transmission Oil Temperature Over Max Limit
Value • 522364.13—TCU Was Unable To Read Clutch
• 522375.0—Transmission Oil Filter Restricted Adjustment Parameters
• 522374.03—TCU Supply Voltage Short To Power
9015B
20
5
TX14826,0000098 –19–14AUG03–5/5

092005
PN=495
References
CAN Monitor Unit (CMU) Diagnostic Trouble

Codes (S.N. 590068— )
The diagnostic trouble code number is indicated by an

(SPN) Suspect Parameter Number and a (FMI) Failure
Mode Indicator number. (2000.09) 2000 is the SPN
number and 09 is the FMI number.
Use SERVICE ADVISOR™ system or see Stored Codes

in the Display Menu to view stored diagnostic trouble
codes.
(2000.09) Missing CAN message from ECU. Check fuse F03, F10. Check wires
M12 yellow and M13 green at ECU
connector. See Engine Controller
Circuit (SE14) in System Functional
Schematic and Section Legend (S.N.
590068— ). (Group 9015B-10.)
9015B (2033.09) Missing CAN message from FLC. Check fuse F15, F21. Check wires
20
6
590068— ). (Group 9015B-10.)
(2003.09) Missing CAN message from TCU. Check fuse F18, F28. Check wires
590068— ). (Group 9015B-10.)
(2140.09) Missing CAN message from SSM. Check fuse F13. Check wires M12
yellow and M13 green at ECU
590068— ). (Group 9015B-10.)

092005
PN=496
References
(829.05) Fuel Level Sensor open or short to Check fuel level sensor and wires
power. Y02 yellow and R02 black. See
Display Monitor Circuit (SE15) in
System Functional Schematic and
Section Legend (S.N. 590068— ).
(Group 9015B-10.)
(2367.04) Left Turn Switch short to ground. Check S25 turn switch and wires
L07 brown and P13 red. See Flasher
and Turn Circuit (SE34) in System
Functional Schematic and Section
Legend (S.N. 590068— ). (Group
9015B-10.)
(2369.04) Right Turn Switch short to ground. Check S25 turn switch and wires
L10 brown and P13 red. See Flasher
and Turn Circuit (SE34) in System
Functional Schematic and Section
9015B-10.) 9015B
20
7
TX14826,0000099 –19–14AUG03–2/2

092005
PN=497
References
Flex Load Controller (FLC) Diagnostic

Trouble Codes (S.N. 590068— )


codes.
(1045.04) Brake light pressure switch shorted Check wire L03 brown, P02 red. See
to ground. FLC Circuit (SE19) connector X41
pin A4 in System Functional
Schematic and Schematic Legend
(S.N. 590068— ). (Group 9015B-10.)
(1071.31) Variable Speed Fan Circuit Fault Check wire H35 green, R35 black.
9015B See FLC Circuit (SE19) connector
20
X42 pin D4, C4 in System Functional
8
(S.N. 590068— ). (Group 9015B-10.)
(117.01) Service Brake Accumulator Low Check hydraulic system. Check wire
N07 yellow, P23 red, . See FLC
Circuit (SE19) connector X40 pin E2
in System Functional Schematic and
Schematic Legend (S.N. 590068— ).
(Group 9015B-10.)
(117.04) Service Brake Accumulator Short To Check fuse F23. Check wire N07
Ground yellow, P23 red, . See FLC Circuit
(SE20) connector X40 pin E2 in
(Group 9015B-10.)
(1638.00) Hydraulic Oil Temperature High. Check fan system. Check hydraulic
system. Clean cooler.
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page TX14826,000009A –19–14AUG03–1/14

092005
PN=498
References
(1638.04) Hydraulic Oil Temperature Circuit Check wire X01 yellow, R68 black.
Shorted To Ground. See FLC Circuit (SE19) connector
X42 pin E4 in System Functional
(S.N. 590068— ). (Group 9015B-10.)
(167.16) System voltage high (Engine Check alternator. Check System

Running). Voltage. See FLC Circuit (SE19)
connector X41 terminal L1 in System
Functional Schematic and Schematic
9015B-10.)
(167.18) System voltage low (Engine Check alternator. Check System

Running). Voltage. See FLC Circuit (SE19)
connector X41 terminal L1 in System
9015B-10.)
9015B
(168.16) System voltage high (Engine Off). Check System Voltage. See FLC 20
9
Circuit (SE19) connector X41
terminal L1 in System Functional
(S.N. 590068— ). (Group 9015B-10.)
(168.18) System voltage low (Engine Off). Check System Voltage. See FLC
Circuit (SE19) connector X41 pin L1
(Group 9015B-10.)
(1713.01) Hydraulic oil filter restricted. Replace hydraulic oil filter.
(1762.03) Hydraulic system pressure sensor Check wire N05 yellow, P69 red,
voltage high. R69 black. See FLC Circuit (SE19)
connector X41 pin D3, K3, K4 in
(Group 9015B-10.)
Continued on next page TX14826,000009A –19–14AUG03–2/14

092005
PN=499
References
(1762.04) Hydraulic system pressure sensor Check wire N05 yellow, P69 red,
voltage low. R69 black. See FLC Circuit (SE19)
connector X41 pin D3, K3, K4 in
(Group 9015B-10.)
(2350.05) Drive light circuit open circuit. Check wire L19 brown, L27 brown,
G05 black. See FLC Circuit (SE18)
connector X40 pin A3, A4 in System
9015B-10.)
(2350.06) Drive light circuit short to ground. Check wire L19 brown, L27 brown,
connector X40 pin A3, A4 in System
9015B 9015B-10.)
20
10
(2356.06) Front work light circuit short to Check wire L02 brown, L24 brown,
ground. G04 black. See FLC Circuit (SE18)
connector X40 pin C3, C4 in System
9015B-10.)
(2356.05) Front work light circuit open circuit. Check wire L02 brown, L24 brown,
connector X40 pin C3, C4 in System
9015B-10.)
(2362.06) Rear work light circuit short to Check wire L25 brown, L26 brown,
connector X40 pin B3, B4 in System
9015B-10.)

092005
PN=500
References
(2362.05) Rear work light circuit open circuit. Check wire L25 brown, L26 brown,
connector X40 pin B3, B4 in System
9015B-10.)
(2366.06) Docking work light circuit short to Check wire L28 brown, L29 brown,
connector X40 pin F3, F4 in System
9015B-10.)
(2366.05) Docking work light circuit open Check wire L28 brown, L29 brown,
circuit. G04 black. See FLC Circuit (SE18)
connector X40 pin F3, F4 in System
9015B-10.) 9015B
20
11
(2368.03) Left turn lights circuit short to power. Check wire L09 brown, G02 black,
connector X42 pin B2 in System
9015B-10.)
(2368.05) Left turn lights circuit open circuit. Check wire L09 brown, G02 black,
9015B-10.)
(2368.06) Left turn lights circuit short to Check wire L09 brown, G02 black,
9015B-10.)

092005
PN=501
References
(2370.03) Right turn lights circuit short to Check wire L12 brown, G02 black,
power. G05 black. See FLC Circuit (SE18)
connector X42 pin C2 in System
9015B-10.)
(2370.05) Right turn lights circuit open circuit. Check wire L12 brown, G02 black,
9015B-10.)
(2370.06) Right turn lights circuit short to Check wire L12 brown, G02 black,
9015B 9015B-10.)
20
12
(2378.03) Marker/Tail lights circuit short to Check wire L06 brown, G02 black,
power. G05 black. See FLC Circuit (SE18)
connector X42 pin D2 in System
9015B-10.)
(2378.05) Marker/Tail lights circuit open circuit. Check wire L06 brown, G02 black,
9015B-10.)
(2378.06) Marker/Tail lights circuit short to Check wire L06 brown, G02 black,
9015B-10.)

092005
PN=502
References
(2386.06) Beacon Light circuit short to ground. Check wire L22 brown, G04 black.
See FLC Circuit (SE18) connector
X40 pin H1, H2 in System Functional
(S.N. 590068— ). (Group 9015B-10.)
(2386.05) Beacon Light circuit short to power. Check wire L22 brown, G04 black.
X40 pin H1, H2 in System Functional
(S.N. 590068— ). (Group 9015B-10.)
(2717.03) A4 Return-to-Dig Detent Coil short to Check wire H23 green, G04 black.
power. See FLC Circuit (SE19) connector
X41 pin H4 in System Functional
(S.N. 590068— ). (Group 9015B-10.)
(2717.06) A4 Return-to-Dig Detent Coil short to Check wire H23 green, G04 black.
ground. See FLC Circuit (SE19) connector 9015B
X41 pin H4 in System Functional 20
13
(S.N. 590068— ). (Group 9015B-10.)
(2875.04) S24 Four Flasher Switch short to check fuse F01. Check wire L20
ground. brown, P01 red. See FLC Circuit
(SE19) connector X41 pin D2 in
(Group 9015B-10.)
(522438.03) Y20 Pin Disconnect Solenoid short Check wire H15 green, G05 black.
to power. See FLC Circuit (SE18) connector
X41 pin F4 in System Functional
(S.N. 590068— ). (Group 9015B-10.)
(522438.05) Y20 Pin Disconnect Solenoid open Check wire H15 green, G05 black.
circuit. See FLC Circuit (SE18) connector
(S.N. 590068— ). (Group 9015B-10.)

092005
PN=503
References
(522438.06) Y20 Pin Disconnect Solenoid short Check wire H15 green, G05 black.
to ground. See FLC Circuit (SE18) connector
(S.N. 590068— ). (Group 9015B-10.)
(522437.04) S17 Return-to-Dig Sensor (Bucket) Check wire H04 green, P11 red,
short to ground. G05 black. See FLC Circuit (SE18)
9015B-10.)
(522436.04) S37 Return-to-Dig Sensor (Forks) Check wire H05 green, P11 red,
short to ground. G05 black. See FLC Circuit (SE18)
9015B-10.)
9015B
20 (299261.02) Machine Configuration Error. Replace software, configure proper
14
machine model.
(444.18) battery voltage imbalance. Charge batteries separately. Check

for battery voltage. See FLC Circuit
(SE19) connector X40 pin F1 in
(Group 9015B-10.)
(523137.01) Steering pressure low. Check for steering pressure. Check

hydraulic system.
(523137.04) Steering system pressure switch Check fuse F23. Check wire N08
short to ground. yellow, P23 red. See FLC Circuit
(SE20) connector X41 pin C1 in
(Group 9015B-10.)
(523214.05) No power from VEC to FLC. Check wire B15 red. See FLC Circuit
(SE19) connector X40 pin H3, H4 in
(Group 9015B-10.)

092005
PN=504
References
(SE19) connector X41 pin L4, M4 in
(Group 9015B-10.)
(Group 9015B-10.)
(Group 9015B-10.)
(SE19) connector X42 pin G1, G2 in 9015B
System Functional Schematic and 20
Schematic Legend (S.N. 590068— ). 15
(Group 9015B-10.)
(SE19) connector X42 pin H3, H4 in
(Group 9015B-10.)
(523436.17) FLC internal timer failure. Replace software.
(523577.03) M8 Secondary Steering Pump short Check wire H13 green. See FLC
to Power. Circuit (SE19) connector X42 pin F1
(Group 9015B-10.)
(523577.05) M8 Secondary Steering Pump open Check wire H13 green. See FLC
circuit. Circuit (SE19) connector X42 pin F1
(Group 9015B-10.)

092005
PN=505
References
(523577.06) M8 Secondary Steering Pump short Check wire H13 green. See FLC
to ground. Circuit (SE19) connector X42 pin F1
(Group 9015B-10.)
(523786.03) B45 Analog Boom Position Sensor Check wire H28 green. See FLC
voltage to high. Circuit (SE19) connector X41 pin E3
(Group 9015B-10.)
(523786.04) B45 Analog BHKO/RTC Position Check wire H28 green. See FLC
Sensor voltage to low. Circuit (SE19) connector X41 pin E3
(Group 9015B-10.)
(523948.03) Y18, Y34 Ride Control Solenoids Check wire H02 green. See FLC
9015B short to power. Circuit (SE19) connector X41 pin G4
20 in System Functional Schematic and
16
(Group 9015B-10.)
open circuit. Circuit (SE19) connector X41 pin G4
(Group 9015B-10.)
short to ground. Circuit (SE19) connector X41 pin G4
(Group 9015B-10.)
(522435.03) Front Wiper (High Speed) short to Check wire A07 orange. See FLC
power. Circuit (SE19) connector X42 pin C1
(Group 9015B-10.)

092005
PN=506
References
(522435.05) Front Wiper (High Speed) open Check wire A07 orange. See FLC
circuit. Circuit (SE19) connector X42 pin C1
(Group 9015B-10.)
(522435.06) Front Wiper (High Speed) short to Check wire A07 orange. See FLC
ground. Circuit (SE19) connector X42 pin C1
(Group 9015B-10.)
(522434.00) Front Wiper (Low Speed) stalled Check wiper arms for binding.
wiper motor.
(522434.05) Front Wiper (Low Speed) open Check wire A08 orange. See FLC
circuit. Circuit (SE19) connector X40 pin E3,
E4 in System Functional Schematic
and Schematic Legend (S.N.
590068— ). (Group 9015B-10.) 9015B
20
17
(522434.06) Front Wiper (Low Speed) short to Check wire A08 orange. See FLC
ground. Circuit (SE19) connector X40 pin E3,
E4 in System Functional Schematic
590068— ). (Group 9015B-10.)
(522427.04) Front Wiper (Park) signal missing. Check wire A09 orange. See FLC
(Group 9015B-10.)
(522797.03) Front Washer Pump short to power. Check wire A04 orange, G02 black.
X42 pin D1 in System Functional
(S.N. 590068— ). (Group 9015B-10.)
(522797.05) Front Washer Pump open circuit. Check wire A04 orange, G02 black.
(S.N. 590068— ). (Group 9015B-10.)

092005
PN=507
References
(522797.06) Front Washer Pump short to ground. Check wire A04 orange, G02 black.
(S.N. 590068— ). (Group 9015B-10.)
(522426.04) Rear Wiper (Park) short to ground. Check wire A13 orange. See FLC
(Group 9015B-10.)
(522432.03) Rear Wiper (High Speed) short to Check wire A11 orange. See FLC
power. Circuit (SE19) connector X42 pin A1
(Group 9015B-10.)
(522432.05) Rear Wiper (High Speed) open Check wire A11 orange. See FLC
9015B circuit. Circuit (SE19) connector X42 pin A1
20 in System Functional Schematic and
18
(Group 9015B-10.)
(522432.06) Rear Wiper (High Speed) short to Check wire A11 orange. See FLC
ground. Circuit (SE19) connector X42 pin A1
(Group 9015B-10.)
(522433.00) Rear Wiper (Low Speed) stalled Check wiper arms for binding.
wiper motor.
(522433.05) Rear Wiper (Low Speed) open Check wire A12 orange. See FLC
circuit. Circuit (SE19) connector X40 pin D3,
D4 in System Functional Schematic
590068— ). (Group 9015B-10.)
(522433.06) Rear Wiper (Low Speed) short to Check wire A12 orange. See FLC
ground. Circuit (SE19) connector X40 pin D3,
D4 in System Functional Schematic
590068— ). (Group 9015B-10.)

092005
PN=508
References
(522796.03) Rear Washer Pump short to power. Check wire A05 orange, G02 black.
X42 pin B1 in System Functional
(S.N. 590068— ). (Group 9015B-10.)
(522796.05) Rear Washer Pump open circuit. Check wire A05 orange, G02 black.
(S.N. 590068— ). (Group 9015B-10.)
(522796.06) Rear Washer Pump short to ground. Check wire A05 orange, G02 black.
(S.N. 590068— ). (Group 9015B-10.)
(785.03) Y14, Y15 Pilot Enable Solenoids Check wire H24 green, G02 black.
short to power. See FLC Circuit (SE19) connector 9015B
X42 pin E1 in System Functional 20
19
(S.N. 590068— ). (Group 9015B-10.)
open circuit. See FLC Circuit (SE19) connector
(S.N. 590068— ). (Group 9015B-10.)
short to ground. See FLC Circuit (SE19) connector
(S.N. 590068— ). (Group 9015B-10.)
(880.03) Brake Lights short to power. Check wire L04 brown, G02 black.
(S.N. 590068— ). (Group 9015B-10.)

092005
PN=509
References
(880.05) Brake Lights open circuit. Check wire L04 brown, G02 black.
(S.N. 590068— ). (Group 9015B-10.)
(880.06) Brake Lights short to ground. Check wire L04 brown, G02 black.
(S.N. 590068— ). (Group 9015B-10.)
(928.03) Y28 Axle Disconnect Solenoid short Check wire H08 green, G01 black.
to power. See FLC Circuit (SE19) connector
(S.N. 590068— ). (Group 9015B-10.)
(928.05) Y28 Axle Disconnect Solenoid open Check wire H08 green, G01 black.
9015B circuit. See FLC Circuit (SE19) connector
20 X41 pin B4 in System Functional
20
(S.N. 590068— ). (Group 9015B-10.)
(928.06) Y28 Axle Disconnect Solenoid short Check wire H08 green, G01 black.
to ground. See FLC Circuit (SE19) connector
(S.N. 590068— ). (Group 9015B-10.)
(977.03) Y38 Reverse Fan Solenoid short to Check wire H26 green, G02 black.
power. See FLC Circuit (SE19) connector
X42 pin A4 in System Functional
(S.N. 590068— ). (Group 9015B-10.)
(977.05) Y38 Reverse Fan Solenoid open Check wire H26 green, G02 black.
circuit. See FLC Circuit (SE19) connector
(S.N. 590068— ). (Group 9015B-10.)

092005
PN=510
References
(977.06) Y38 Reverse Fan Solenoid short to Check wire H26 green, G02 black.
ground. See FLC Circuit (SE19) connector
(S.N. 590068— ). (Group 9015B-10.)
(1079.04) FLC Sensor supply voltage short to Check wire P68 red, R68 black. See
ground. FLC Circuit (SE19) connector X41
pin K1, K2 in System Functional
(S.N. 590068— ). (Group 9015B-10.)
(1080.04) FLC Sensor supply voltage short to Check wire P68 red, R68 black. See
ground. FLC Circuit (SE19) connector X41
pin K1, K2 in System Functional
(S.N. 590068— ). (Group 9015B-10.)
(2000.19) CAN fault, missing message from Check fuse F10, F03. Check wire
ECU. M12 yellow, M13 green in controller 9015B
connectors X13 pin 4G and X18 pin 20
21
12 G.
TCU. M12 yellow, M13 green, P18 red,
P28 red in connectors X23 pin 25
and X23 pin 23, 45, 68.
CMU. M12 yellow, M13 green, P13 red,
P34 red in connectors X48 pin L, A
and X48 pin C, K.
SSM. M12 yellow, M13 green, P13 red in
connectors X17 pin 11F.
(524265.19) Data error. Internal Update software.

Hardware/Software problem
(522431.2) Hardware failure. Update software.
TX14826,000009A –19–14AUG03–14/14

092005
PN=511
References
Sealed Switch Module (SSM) Diagnostic



codes.
(523523.10) Rear wiper key pad stuck or SSM Check SSM Module. See SSM
Failure. Module Circuit (SE39) in System
9015B-10.)
(523524.10) Front wiper key pad stuck or SSM Check SSM Module. See SSM
9015B Failure. Module Circuit (SE39) in System
20
22
9015B-10.)
(523525.10) Front Washer key pad stuck or SSM Check SSM Module. See SSM
9015B-10.)
(523526.10) Reverse fan key pad stuck or SSM Check SSM Module. See SSM
9015B-10.)
(523527.10) Reverse fan key pad stuck or SSM Check SSM Module. See SSM
9015B-10.)
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page TX14826,000009B –19–14AUG03–1/4

092005
PN=512
References
(523528.10) A/C key pad stuck or SSM Failure. Check SSM Module. See SSM
Module Circuit (SE39) in System
9015B-10.)
(523529.10) Work Lights key pad stuck or SSM Check SSM Module. See SSM
9015B-10.)
(523530.10) Beacon Light key pad stuck or SSM Check SSM Module. See SSM
9015B-10.)
(523531.10) Axle Disconnect key pad stuck or Check SSM Module. See SSM
SSM Failure. Module Circuit (SE39) in System 9015B
Functional Schematic and Schematic 20
23
9015B-10.)
(523532.10) Spin Control key pad stuck or SSM Check SSM Module. See SSM
9015B-10.)
(523533.10) Clutch Cut-Off key pad stuck or SSM Check SSM Module. See SSM
9015B-10.)
(523534.10) Pilot Enable key pad stuck or SSM Check SSM Module. See SSM
9015B-10.)
Continued on next page TX14826,000009B –19–14AUG03–2/4

092005
PN=513
References
(523535.10) Ride Control key pad stuck or SSM Check SSM Module. See SSM
9015B-10.)
(523536.10) Auto Transmission key pad stuck or Check SSM Module. See SSM
SSM Failure. Module Circuit (SE39) in System
9015B-10.)
(523537.10) Drive Lights key pad stuck or SSM Check SSM Module. See SSM
9015B-10.)
(523538.10) Key pad not used. Check SSM Module. See SSM
9015B Module Circuit (SE39) in System
20 Functional Schematic and Schematic
24
9015B-10.)
(523607.10) Return-to-Dig key pad stuck or SSM Check SSM Module. See SSM
9015B-10.)
(523608.10) Boom Height Kickout key pad stuck Check SSM Module. See SSM
or SSM Failure. Module Circuit (SE39) in System
9015B-10.)
(523609.10) Return-to-Carry key pad stuck or Check SSM Module. See SSM
SSM Failure. Module Circuit (SE39) in System
9015B-10.)
Continued on next page TX14826,000009B –19–14AUG03–3/4

092005
PN=514
References
(523610.10) Rear Washer key pad stuck or SSM Check SSM Module. See SSM
9015B-10.)
(629.12) SSM lost communications. Update software.
(2033.09) CAN communication lost for FLC. Check fuse F15, F21. Check
connections and CAN network wires
M12 Yellow, M13 green, P13 red.
X41 connector, pins A1, B1, M1, L1.
See FLC Module Circuit (SE19) in
(Group 9015B-10.)
(639.12) SSM lost message. Check fuse F13. Check connections

and CAN network wires M12 Yellow,
M13 green, P13 red. See ECU 9015B
Module Circuit (SE41) in System 20
Functional Schematic and Schematic 25
9015B-10.)
(639.19) SSM lost communications. Check fuse F13. Check connections

and CAN network, wires M12
Yellow, M13 green, P13 red. See
ECU Module Circuit (SE41) in
(Group 9015B-10.)
TX14826,000009B –19–14AUG03–4/4

092005
PN=515
References
Transmission Control Unit (TCU) Diagnostic



codes.
(522421.02) FLC or CMU is defective or Check CAN bus network for

interference on CAN bus. message. See Controller Area
Network (CAN) Theory of Operation
(S.N. 590068— ). (Group 9015B-15.)
(522420.02) FLC or CMU is defective or Check CAN bus network for

9015B Network (CAN) Theory of Operation
20
(S.N. 590068— ). (Group 9015B-15.)
26
(522419.02) FLC or SSM is defective or Check CAN bus network for

Network (CAN) Theory of Operation
(S.N. 590068— ). (Group 9015B-15.)
(522418.02) Clutch K1 calculated value is out of Low clutch pressure. Low main
range. pressure. Sensor out of adjustment.
Check B30 internal speed sensor
and B31 transmission output shaft
speed sensor specifications. See
(S.N. 590068— ). (Group 9015B-20.)
(S.N. 590068— ). (Group 9015B-20.)
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page TX14826,000009D –19–14AUG03–1/13

092005
PN=516
References
(S.N. 590068— ). (Group 9015B-20.)
(S.N. 590068— ). (Group 9015B-20.)
(522414.02) Clutch KV calculated value is out of Low clutch pressure. Low main
and B31 transmission output shaft 9015B
speed sensor specifications. See 20
27
(S.N. 590068— ). (Group 9015B-20.)
(522413.02) Clutch KR calculated value is out of Low clutch pressure. Low main
(S.N. 590068— ). (Group 9015B-20.)
(522412.12) Gear Selector Fault Check connector X23 pin 20, 23, 65,
wire T10 blue, T11 blue, T12 blue.
See Transmission Controller Circuit
(SE23) in System Functional
(S.N. 590068— ). (Group 9015B-10.)
Continued on next page TX14826,000009D –19–14AUG03–2/13

092005
PN=517
References
(522411.12) FNR Selector Fault Check connector X23 pin 22, 43, 64,
67, wire T13 blue, T14 blue, T15
blue, T16 blue. See Transmission
Controller Circuit (SE23) in System
9015B-10.)
(522410.12) Engine Does Not Derate. TCU and Check CAN bus wiring. See
ECU Not Communicating. Controller Area Network (CAN)
). (Group 9015B-15.)
(522409.12) FNR Selector #2 Selector Fault Check connector X23 pin 22, 43, 64,
67, wire T13 blue, T14 blue, T15
blue, T16 blue. See Transmission
9015B 9015B-10.)
20
28
(522407.03) Clutch Cut-Off Sensor short to Check connector X23 pin 24, 37, 38,
power. wire T20 blue, P77 red, R77 black.
(S.N. 590068— ). (Group 9015B-10.)
(522407.04) Clutch Cut-Off Sensor short to Check connector X23 pin 24, 37, 38,
ground. Open circuit. wire T20 blue, P77 red, R77 black.
(S.N. 590068— ). (Group 9015B-10.)
(522406.03) Transmission Oil Temperature Check connector X23 pin 39, 46,
Sensor short to power. Open circuit. wire X06 yellow, R06 black. See
Transmission Controller Circuit
(S.N. 590068— ). (Group 9015B-10.)

092005
PN=518
References
(522406.04) Transmission Oil Temperature Check connector X23 pin 39, 46,
Sensor short to ground. wire X06 yellow, R06 black. See
(S.N. 590068— ). (Group 9015B-10.)
(522405.03) Park Brake Switch short to power. Check fuse F23. Check connector
Open circuit. X23 pin 30, 46, wire N04 yellow,
P23 red. See Transmission
9015B-10.)
(522405.04) Park Brake Switch short to ground. Check fuse F23. Check connector
X23 pin 30, 46, wire N04 yellow,
P23 red. See Transmission
Functional Schematic and Schematic 9015B
Legend (S.N. 590068— ). (Group 20
29
9015B-10.)
(522404.03) Torque Converter Input Speed Check connector X23 pin 19, 3, wire
Sensor short to power. Open circuit. M07 purple, R09 black. See
(S.N. 590068— ). (Group 9015B-10.)
(522404.04) Torque Converter Input Speed Check connector X23 pin 19, 3, wire
Sensor short to ground. M07 purple, R09 black. See
(S.N. 590068— ). (Group 9015B-10.)
(522404.12) Torque Converter Input Speed Check B28 Torque Converter Input
Sensor open circuit. Speed Sensor gap and sensor
defect. Sensor out of adjustment.
Specifications (S.N. 590068— ).
(Group 9015B-20.)

092005
PN=519
References
(522403.03) Torque Converter Output Speed B29 Torque Converter Output Speed
Sensor short to power. Open circuit. Sensor. Check connector X23 pin
41, 3, wire M08 purple, R09 black.
(S.N. 590068— ). (Group 9015B-10.)
(522403.04) Torque Converter Output Speed B29 Torque Converter Output Speed
Sensor short to ground. Sensor. Check connector X23 pin
41, 3, wire M08 purple, R09 black.
(S.N. 590068— ). (Group 9015B-10.)
(522403.12) Torque Converter Output Speed Check B29 Torque Converter Output
Sensor open circuit. Speed Sensor gap and sensor
9015B See Electrical Component
20 Specifications (S.N. 590068— ).
30
(Group 9015B-20.)
(522402.03) Transmission Internal Clutch Speed Check connector X23 pin 42, 3, wire
Sensor short to power. Open circuit. M09 purple, R09 black. See
(S.N. 590068— ). (Group 9015B-10.)
(522402.04) Transmission Internal Clutch Speed Check connector X23, pin 42, 3, wire
Sensor short to ground. M09 purple, R09 black. See
(S.N. 590068— ). (Group 9015B-10.)
(522402.12) Transmission Internal Clutch Speed Check B30 Transmission Internal

Sensor open circuit. Clutch Speed Sensor gap and
sensor defect. Sensor out of
adjustment. See Electrical
Component Specifications (S.N.
590068— ). (Group 9015B-20.)

092005
PN=520
References
(522401.03) Transmission Output Speed Sensor Check connector X23, pin 62, 4,
short to power. Open circuit. X10, pin 1H, wire M10 purple, P40
red, R40 black. See Transmission
9015B-10.)
(522401.04) Transmission Output Speed Sensor Check connector X23, pin 62, 4,
short ground. X10, pin 1H, wire M10 purple, P40
red, R40 black. See Transmission
9015B-10.)
(522401.12) Transmission Output Speed Sensor Check B31 Transmission Output

open circuit. Speed Sensor gap and sensor
See Electrical Component 9015B
Specifications (S.N. 590068— ). 20
31
(Group 9015B-20.)
(522401.02) Transmission Output Speed Sensor Check B31 Transmission Output

shifts to neutral. Speed Sensor gap and sensor
(Group 9015B-20.)
(2023.09) TCU CAN communication lost for Check fuse F13 and F34. Check
CMU. connector X48, pin L, A, C, K. See
CMU Circuit (SE14) in System
9015B-10.)
(2033.09) TCU CAN communication lost for Check fuse F15 and F21. Check
FLC. connector X41, pin A1, B1, M1, L1.
See FLC Circuit (SE19) in System
9015B-10.)

092005
PN=521
References
(522421.02) CAN signal for automatic downshift Check CAN bus wiring. See
is defective. Controller Area Network (CAN)
). (Group 9015B-15.)
(522420.02) CAN signal for manual downshift is Check CAN bus wiring. See
defective. Controller Area Network (CAN)
). (Group 9015B-15.)
(522419.02) CAN signal for clutch cut-off is Check CAN bus wiring. See
defective. Controller Area Network (CAN)
). (Group 9015B-15.)
(522399.03) Y1 solenoid short to power. Check connector X23, pin 12, 13,
56, wire T03 blue, P78 red. See
9015B Schematic and Schematic Legend
20 (S.N. 590068— ). (Group 9015B-10.)
32
(522399.04) Y1 solenoid short to ground. Check connector X23, pin 12, 13,
(S.N. 590068— ). (Group 9015B-10.)
(522398.05) Y1 solenoid open circuit. Check connector X23, pin 12, 13,
(S.N. 590068— ). (Group 9015B-10.)
(S.N. 590068— ). (Group 9015B-10.)

092005
PN=522
References
(S.N. 590068— ). (Group 9015B-10.)
(S.N. 590068— ). (Group 9015B-10.)
(S.N. 590068— ). (Group 9015B-10.) 9015B
20
33
(S.N. 590068— ). (Group 9015B-10.)
(S.N. 590068— ). (Group 9015B-10.)
(S.N. 590068— ). (Group 9015B-10.)

092005
PN=523
References
(S.N. 590068— ). (Group 9015B-10.)
(S.N. 590068— ). (Group 9015B-10.)
(522388.03) Y5 solenoid short to power. Check connector X23, pin 9, 12, 13,
wire T07 blue, P78 red. See
9015B (S.N. 590068— ). (Group 9015B-10.)
20
34
(522387.04) Y5 solenoid short to ground. Check connector X23, pin 9, 12, 13,
(S.N. 590068— ). (Group 9015B-10.)
(522386.05) Y5 solenoid open circuit. Check connector X23, pin 9, 12, 13,
(S.N. 590068— ). (Group 9015B-10.)
(S.N. 590068— ). (Group 9015B-10.)

092005
PN=524
References
(S.N. 590068— ). (Group 9015B-10.)
(S.N. 590068— ). (Group 9015B-10.)
(522382.03) H3 Back-Up Alarm short to power. Check fuse F32. Check connector
X23, pin 7, wire M28 purple, P32
red. See Transmission Controller
(S.N. 590068— ). (Group 9015B-10.) 9015B
20
35
(522381.04) H3 Back-Up Alarm short to ground. Check fuse F32. Check connector
(S.N. 590068— ). (Group 9015B-10.)
(522380.05) H3 Back-Up Alarm open circuit. Check fuse F32. Check connector
(S.N. 590068— ). (Group 9015B-10.)
(522379.03) Y19 Park Brake Solenoid short to Check connector X23, pin 8, 33, 53,
power. wire T09 blue, P79 red. See
(S.N. 590068— ). (Group 9015B-10.)

092005
PN=525
References
(522378.04) Y19 Park Brake Solenoid short to Check connector X23, pin 8, 33, 53,
ground. wire T09 blue, P79 red. See
(S.N. 590068— ). (Group 9015B-10.)
(522377.05) Y19 Park Brake Solenoid open Check connector X23, pin 8, 33, 53,
circuit. wire T09 blue, P79 red. See
(S.N. 590068— ). (Group 9015B-10.)
(522376.0) Transmission oil temperature over Check transmission oil temperature.

max value. Check B32 transmission oil
temperature sensor. See
9015B Schematic.
20
36
(522375.0) Transmission Oil Filter restricted. Check and replace transmission oil
filter. Check and replace
transmission oil filter restriction
switch. See Transmission Controller
(S.N. 590068— ). (Group 9015B-10.)
(522374.03) Transmission Oil Temperature Check connector X23, pin 37, wire
Sensor short to power. P77 red. See Transmission
9015B-10.)
(522374.04) Transmission Oil Temperature Check connector X23, pin 37, wire
Sensor short to ground. P77 red. See Transmission
9015B-10.)

092005
PN=526
References
(522373.03) TCU Supply Voltage High Check fuse F18, F28. Check
connector X23, pin 23, 45, 68, wire
P18 red, P28 red. See Transmission
9015B-10.)
(522372.04) TCU Supply Voltage Low Check fuse F18, F28. Check
connector X23, pin 23, 45, 68, wire
P18 red, P28 red. See Transmission
9015B-10.)
(522371.02) TCU Supply Voltage shorted to Check connector X23, pin 12, 13,
power or ground. wire P78 red. See Transmission
Functional Schematic and Schematic 9015B
Legend (S.N. 590068— ). (Group 20
37
9015B-10.)
(522370.02) TCU Supply Voltage shorted to Check connector X23, pin 12, 13,
power or ground. wire P78 red. See Transmission
9015B-10.)
(522369.03) X1 Service ADVISOR System Check X1 Service ADVISOR System

Connector shorted to power. Connector, wires Z12, Z13, Z14
gray. See Transmission Controller
(S.N. 590068— ). (Group 9015B-10.)
(522369.04) X1 Service ADVISOR System Check X1 Service ADVISOR System

Connector shorted to ground. Connector, wires Z12, Z13, Z14
gray. See Transmission Controller
(S.N. 590068— ). (Group 9015B-10.)
(522368.02) TCU memory failure. Replace software, replace TCU.

092005
PN=527
References
(522367.13) TCU configuration lost. Replace software, replace TCU.
(522366.13) TCU application error. Replace software, replace TCU
(522365.13) TCU limp home request. Check for other codes active or
stored.
(522364.07) Transmission clutch adjustment out See transmission repair.

of limit.
(522364.13) TCU unable to read clutch See transmission repair.

adjustment parameters.
TX14826,000009D –19–14AUG03–13/13
9015B
20
38

092005
PN=528
References
Engine Control Unit (ECU) Diagnostic



codes.
000091.09 Throttle Invalid See 000091.09 - Throttle Invalid in

000094.03 Fuel Rail Pressure Input Voltage See 000094.03 FUEL RAIL
High PRESSURE INPUT VOLTAGE
HIGH DIAGNOSTIC PROCEDUREin
9015B
20
000094.04 Fuel Rail Pressure Input Voltage See 000094.03 FUEL RAIL
39
Low PRESSURE INPUT VOLTAGE LOW
000094.10 Fuel Rail Pressure Loss Detected See 000094.10 FUEL RAIL
PRESSURE LOSS DETECTED
000094.17 Fuel Rail Pressure Not Developed See 000094.17 FUEL RAIL
PRESSURE NOT DEVELOPED
000097.03 Water in Fuel Signal Voltage High See 000097.03 WATER IN FUEL
SIGNAL VOLTAGE HIGH
000097.04 Water in Fuel Signal Voltage Low See 000097.04 WATER IN FUEL
SIGNAL VOLTAGE LOW
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page TX14826,000009C –19–01AUG03–1/8

092005
PN=529
References
000097.16 Water in Fuel Detected See 000097.16 WATER IN FUEL

DETECTED DIAGNOSTIC
160 of CTM255.
000105.03 Manifold Air Temperature Input See 000105.03 MANIFOLD AIR

Voltage High TEMPERATURE INPUT VOLTAGE
CTM255.
000105.04 Manifold Air Temperature Input See 000105.04 MANIFOLD AIR

Voltage Low TEMPERATURE INPUT VOLTAGE
000105.16 Manifold Air Temperature Moderately See 000105.16 MANIFOLD AIR

High TEMPERATURE MODERATELY
9015B in Section 04, Group 160 of
20 CTM255.
40
000110.00 Engine Coolant Temperature High See 000110.00 ENGINE COOLANT

Extremely High TEMPERATURE HIGH MOST
SEVERE DIAGNOSTIC
160 of CTM255.
000110.03 Engine Coolant Temperature Input See 000110.03 ENGINE COOLANT

Voltage High TEMPERATURE INPUT VOLTAGE
CTM255.
000110.04 Engine Coolant Temperature Input See 000110.04 ENGINE COOLANT

Voltage Low TEMPERATURE INPUT VOLTAGE
000110.16 Engine Coolant Temperature See 000110.16 ENGINE COOLANT

Moderately High TEMPERATURE HIGH
MODERATELY SEVERE
Continued on next page TX14826,000009C –19–01AUG03–2/8

092005
PN=530
References
000158.17 ECU Power Down Error See 000158.17 ECU POWER

DOWN ERROR DIAGNOSTIC
160 of CTM255.
000174.03 Fuel Temperature Input Voltage High See 000174.03 FUEL

CTM255.
000174.04 Fuel Temperature Input Voltage Low See 000174.04 FUEL

000174.16 Fuel Temperature High Moderately See 000174.16 FUEL

Severe TEMPERATURE HIGH
MODERATELY SEVERE
DIAGNOSTIC PROCEDURE in 9015B
Section 04, Group 160 of CTM255. 20
41
000611.03 Electronic Injector Wiring Shorted To See 000611.03 ELECTRONIC

Power Source INJECTOR WIRING SHORTED TO
POWER SOURCE DIAGNOSTIC
160 of CTM255.
000611.04 Electronic Injector Wiring Shorted To See 000611.04 ELECTRONIC

Ground INJECTOR WIRING SHORTED TO
GROUND DIAGNOSTIC
160 of CTM255.
000620.03 Sensor Supply 1 Voltage High See 000620.03 SENSOR SUPPLY 1

160 of CTM255.
000620.04 Sensor Supply 1 Voltage Low See 000620.04 SENSOR SUPPLY 1

160 of CTM255.

092005
PN=531
References
000627.01 Electronic Injector Supply Voltage See 000627.01 ELECTRONIC

Problem INJECTOR SUPPLY VOLTAGE
PROBLEM DIAGNOSTIC
160 of CTM255.
000629.13 ECU Error See 000629.13 ECU ERROR in

000636.02 Pump Position Sensor Input Noise See 000636.02 PUMP POSITION
SENSOR INPUT NOISE
000636.08 Pump Position Sensor Input Missing See 000636.08 PUMP POSITION
SENSOR INPUT MISSING
9015B 000636.10 Pump Position Sensor Input Pattern See 0006360.10 PUMP POSITION
20 Error SENSOR INPUT PATTERN ERROR
42
000637.02 Crank Position Input Noise See 000636.02 CRANK POSITION

INPUT NOISE DIAGNOSTIC
160 of CTM255.
000637.07 Crank Position/Pump Position Timing See 000637.07 CRANK

Moderately Out of Sync POSITION/PUMP POSITION
TIMING MODERATELY OUT OF
SYNC DIAGNOSTIC PROCEDURE
CTM255.
000637.08 Crank Position Input Missing See 000637.08 CRANK POSITION

INPUT MISSING DIAGNOSTIC
160 of CTM255.
000637.10 Crank Position Input Pattern Error See 000637.10 CRANK POSITION
INPUT PATTERN ERROR

092005
PN=532
References
000639.13 CAN Bus Error See 000639.13 CAN BUS ERROR

000651.05 Cylinder #1 EI Circuit Open See 0006510.05 CYLINDER #1 EI

CIRCUIT OPEN DIAGNOSTIC
160 of CTM255.
000651.06 Cylinder #1 EI Circuit Shorted See 0006510.06 CYLINDER #1 EI

CIRCUIT SHORTED DIAGNOSTIC
160 of CTM255.
000651.07 Cylinder #1 EI Fuel Delivery Failure See 000651.07 CYLINDER #1 EI

FUEL DELIVERY FAILURE
000652.05 Cylinder #2 EI Circuit Open See 000652.05 CYLINDER #2 EI 9015B

CIRCUIT OPEN DIAGNOSTIC 20
43
160 of CTM255.

160 of CTM255.


160 of CTM255.

160 of CTM255.

092005
PN=533
References


160 of CTM255.

160 of CTM255.

9015B
20 000655.05 Cylinder #5 EI Circuit Open See 000655.05 CYLINDER #5 EI
44
160 of CTM255.

160 of CTM255.


160 of CTM255.

160 of CTM255.

092005
PN=534
References

001080.03 Fuel Rail Pressure Sensor Supply See 001080.03 FUEL RAIL
Voltage High PRESSURE SENSOR SUPPLY
160 of CTM255.
001080.04 Fuel Rail Pressure Sensor Supply See 001080.04 FUEL RAIL
Voltage Low PRESSURE SENSOR SUPPLY
160 of CTM255.
001347.05 Pump Control Valve #1 Error See 001347.05 PUMP CONTROL

VALVE #1 ERROR DIAGNOSTIC
PROCEDURE in Section 04, Group 9015B
160 of CTM255. 20
45
001347.07 Fuel Rail Pressure Control Error See 001347.07 FUEL RAIL
PRESSURE CONTROL ERROR
001347.10 Pump Control Valve #1 Fuel Flow See 001347.10 PUMP CONTROL
Not Detected VALVE #1 FUEL FLOW NOT
DETECTED DIAGNOSTIC
160 of CTM255.
001348.05 Pump Control Valve #2 Error See 001348.05 PUMP CONTROL

VALVE #2 ERROR DIAGNOSTIC
160 of CTM255.
001348.10 Pump Control Valve #2 Fuel Flow See 001348.10 PUMP CONTROL
Not Detected VALVE #2 FUEL FLOW NOT
DETECTED DIAGNOSTIC
160 of CTM255.

092005
PN=535
References
001568.02 Torque Curve Selection Invalid See 001568.02 TORQUE CURVE

SELECTION INVALID in Section 04,
001569.31 Fuel Derate See 001569.31 FUEL DERATE in

TX14826,000009C –19–01AUG03–8/8
9015B
20
46

092005
PN=536
References
Flex Load Controller (FLC) Fault Exceptions

(S.N. 590068— )
The Flex Load Controller (FLC) controls the functions that

are hardwired to the controller using three types of high
current output drivers. The driver is a solid state device
that acts like a relay, using the internal microcontroller’s
low voltage outputs to control 24 volt, high current signals.
The three different drivers are:
• Dual Channel 3 A (per channel) Driver

• Single Channel 6 A Driver
• Single Channel 20 A Driver
Dual Channel 3 A Driver Usage
NOTE: Functions are paired on most of the dual channel

drivers; however, some are paired with an unused
output. These are labeled as “SPARE”.
• Driver #1 and #2
– Left and Right Brake Lights (E16, E17) 9015B
20
– SPARE
47
– Rear Washer Pump (M4)
– Rear Wiper High Speed (M5)
– Front Washer Pump (M2)
– Front Wiper High Speed (M3)
– Secondary Steering Pump (M8)
– Pilot Enable Solenoid (Y14), Boom Down
Accumulator Solenoid (Y15)
– Axle Disconnect Solenoid (Y28)
– Reverse Fan Solenoid (Y38)
– Pin Disconnect Solenoid (Y20)
– Ride Control (On/Off) Solenoids (Y18, Y34)
– Float Detent Coil
– Ride Control Boom Solenoid (Y17)
– Return-to-Dig Detent Coil
– SPARE
Continued on next page OUT1738,000016B –19–28OCT03–1/3

092005
PN=537
References
– Right Turn Lights(E4, E5)

– Left Turn Lights(E2, E3)
– Boom Height Kickout Detent Coil
– A/C Compressor Clutch Solenoid (Y16)
– SPARE
– Marker Lights, Tail Lights, License Plate Light (E6,
E7, E8, E9, E10)
6 A Driver Usage
NOTE: These drivers are one channel with two outputs.
• Driver #19—Left and Right Drive Lights (E11, E12)

• Driver #20—Left and Right Rear Work Lights (E22,
E23)
• Driver #21—Rear Wiper Low Speed (M5)
• Driver #22—Front Wiper Low Speed (M3)
• Driver #23—Left and Right Front Work Lights (E20,
E21)
• Driver #29—Left and Right Docking Lights (E24, E25)
9015B
20 20 A Driver Usage
48
• Driver #24—Beacon Light (E15)
The FLC has the capability to detect driver faults (open

circuits, short circuits, etc.) and display Diagnostic Trouble
Codes (DTCs) for these faults. There are certain
situations that the FLC does not have the ability to detect
the proper fault. Following is a summary of the known
exceptions.
• On a single channel driver, the FLC cannot tell the

difference between an open circuit and a short to
power, or a short to ground and an overload.
• When changing the model in the CMU, the monitor
alarm will sound if the setting was stored correctly. If
the monitor does not sound, the keyswitch must be
cycled before changing options for them to be stored
correctly.
• If the beacon light (E15) output reaches a 20 A load,
the driver will shut off and the function must be turned
off then on to reset the driver.
• A short to power for the reverse fan solenoid (Y38)
cannot be detected if the brake lights (E16, E17) are
on, regardless if the function is enabled or disabled.
Continued on next page OUT1738,000016B –19–28OCT03–2/3

092005
PN=538
References
• Multiple faults on the same dual channel 3 A driver may

result in an unexpected DTC for the circuits controlled
by the driver.
• If the high speed and low speed wires are swapped on
the front or rear wiper motor (M3 or M5), high speed will
operate the wiper at low speed, low speed will operate
like intermittent, and intermittent will not park correctly.
• If both outputs on a dual channel 3 A driver are open
circuit and one channel is turned one, the result is an
open circuit fault for both channels.
• On a dual channel 3 A or single channel 6 A driver, if
one output is shorted to ground and the other output is
an open circuit, the result is a high current fault for both
outputs.
• On a dual channel 3 A or single channel 6 A driver, if
one output is shorted to power and the other output is
an open circuit, no DTCs will be active as a result.
• A short to power can only be detected on a dual
channel 3 A driver output if the function is turned off.
• A short to power can only be detected on a single
channel 6 A driver output if the function is turned on.
• On a dual channel 3 A driver, if one channel is spare or 9015B
option that is not enabled and it is shorted to power, the 20
49
resulting fault is a short to power on the other channel.
• If a short to ground exists on a dual channel 3 A driver,
the output will not reset every second.
• If a short to ground exists on a single channel 6 A
driver, the output will reset every 5 seconds up to 20
consecutive times.
• If a short to ground exists on a single channel 20 A
driver, the function must be turned off then on to reset
the output.
• If a fault exists for an output, that fault must be cleared
by turning the function off then on before a different
fault for the same output can exist.
• If the FLC is not receiving the park signal from a wiper
motor and the corresponding washer pump is activated,
the wiper will cycle 6 times before stopping.
• If a wiper is stalled and high speed is selected, a park
signal fault will result.
• If the wiper motor is disconnected or an open circuit in
the park signal exists, the CMU will display the wiper in
park position.
OUT1738,000016B –19–28OCT03–3/3

092005
PN=539
References
Check Battery Electrolyte Level and

Terminals (S.N. 590068— )
CAUTION: Battery gas can explode. Keep

sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
NEVER check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.
ALWAYS remove grounded (-) battery clamp

first and replace it last.
Sulfuric acid in battery electrolyte is poisonous.

It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
Avoid the hazard by:
–UN–23AUG88
9015B
20 1. Filling batteries in a well-ventilated area.
50 2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
TS203
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 15—30
minutes. Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do
not exceed 1.9 L (2 quarts).
3. Get medical attention immediately.
1. Remove battery box cover.
Continued on next page OUT1738,0000151 –19–30JUL03–1/3

092005
PN=540
References
IMPORTANT: If water is added to batteries during

freezing weather, batteries must be
charged after water is added to prevent
batteries from freezing. Charge battery
using a battery charger or by running
the engine.
–UN–09SEP03
2. Fill each cell to within specified range with distilled
water. DO NOT overfill.
T6996DB
CAUTION: Prevent possible injury. ALWAYS
remove grounded (-) battery clamp first and
replace it last.
3. Disconnect battery clamps, grounded clamp first.
A—Battery Post
B—Fill Tube
–UN–09SEP03
C—Electrolyte Level Range
9015B
20
T6996DA
51
OUT1738,0000151 –19–30JUL03–2/3
4. Clean battery terminals (A) and clamps with a stiff

brush.
5. Apply lubricating grease (B) around battery terminal

base only.
–UN–21OCT88
6. Install and tighten clamps, grounded clamp last.
T6758AA
OUT1738,0000151 –19–30JUL03–3/3

092005
PN=541
References
Procedure For Testing Batteries (S.N.

590068— )
Visual Check
1. Check for damage such as cracked or broken case

and electrolyte leakage.
If damage is seen, replace battery.
2. Check electrolyte level. (See procedure in this group)
If low, add distilled water to specified level and charge

battery.
3. Check terminals for corrosion.
If corroded, clean using a wire brush or battery post

cleaner such as JT05838 Battery Post/Clamp Cleaner.
4. Check posts for looseness.

9015B
20
If posts are loose, replace battery.
52
Hydrometer Test
1. Check specific gravity with a hydrometer or battery

tester such as JT05460 Coolant/Battery Tester.
2. Record specific gravity reading for each cell.

average specific gravity is between 1.225 and 1.280,
battery is fully charged, go to LOAD TEST.

average specific gravity is LESS than 1.225, charge
battery and repeat test. If average specific gravity is
still LESS than 1.225, replace both batteries.
If high and low readings vary MORE than 0.050,

charge battery and repeat test. If high and low
readings still vary MORE than 0.050, replace both
batteries.
Specification
Hydrometer Test—Specific
gravity ............................................................ 1.225—1.280 Fully charged
Specific gravity ................................................... Under 1.225 Discharged

092005
PN=542
References
Load Test
1. Check battery capacity with a load tester such as

JT05832 Battery Load Tester. Follow tester
manufacturer’s instructions for proper load test
procedures.
2. If one battery fails load test, replace both batteries.
TX,20,111119 –19–01AUG96–2/2
9015B
20
53

092005
PN=543
References
Electrical Component Specifications (S.N.

590068— )
B1—Engine Coolant Temperature Resistance 90—108 kΩ @ -40°C (-40°F)

Sensor 26—31 kΩ @ -20°C (-4°F)
8.7—10.2 kΩ @ 0°C (32°F)
3.3—3.8 kΩ @ 20°C (68°F)
1.4—1.6 kΩ @ 40°C (104°F)
648—708 Ω @ 60°C (140°F)
317—350 Ω @ 80°C (176°F)
170—186 Ω @ 100°C (212°F)
97—105 Ω @ 120°C (248°F)
B3—Camshaft Position Sensor Resistance 2.7—3.3 kΩ
B4—Crankshaft Position Sensor Resistance 2.7—3.3 kΩ
B5—Fuel Temperature Sensor Resistance 90—108 kΩ @ -40°C (-40°F)

26—31 kΩ @ -20°C (-4°F)
9015B 8.7—10.2 kΩ @ 0°C (32°F)
20
3.3—3.8 kΩ @ 20°C (68°F)
54
1.4—1.6 kΩ @ 40°C (104°F)
648—708 Ω @ 60°C (140°F)
317—350 Ω @ 80°C (176°F)
170—186 Ω @ 100°C (212°F)
97—105 Ω @ 120°C (248°F)
B6—Fuel Rail Pressure Sensor Operating pressure 0—180 MPa

0—1800 bar
0—26 100 psi
B7—Manifold Air Temperature Resistance 90—108 kΩ @ -40°C (-40°F)

Sensor 26—31 kΩ @ -20°C (-4°F)
8.7—10.2 kΩ @ 0°C (32°F)
3.3—3.8 kΩ @ 20°C (68°F)
1.4—1.6 kΩ @ 40°C (104°F)
648—708 Ω @ 60°C (140°F)
317—350 Ω @ 80°C (176°F)
170—186 Ω @ 100°C (212°F)
97—105 Ω @ 120°C (248°F)
B14—Analog Throttle Position Resistance between pins A and B 280—420 Ω Minimum Value
Sensor 4.28—6.42 kΩ Maximum Value
Resistance Between Pins A and C 4—6 kΩ

092005
PN=544
References
B15—Hydraulic Oil Temperature Resistance 90—108 kΩ @ -40°C (-40°F)

Sensor 26—31 kΩ @ -20°C (-4°F)
8.7—10.2 kΩ @ 0°C (32°F)
3.3—3.8 kΩ @ 20°C (68°F)
1.4—1.6 kΩ @ 40°C (104°F)
648—708 Ω @ 60°C (140°F)
317—350 Ω @ 80°C (176°F)
170—186 Ω @ 100°C (212°F)
97—105 Ω @ 120°C (248°F)
B17—Fuel level Sensor Resistance 168—192 Ω @ 100% Fill (Full)

91—109 Ω @ 50% Fill
4—16 Ω @ 0% Fill (Empty)
B19—Engine Air Filter Restriction Closing pressure 4.98—7.48 kPa

Switch 1.47—2.2 in. of Hg
20—30 in. of H2O
B20—Transmission Oil Filter Opening pressure 276—414 kPa

Restriction Switch 2.7—4.1 bar 9015B
40—60 psi 20
55
B21—Hydraulic Oil Filter Restriction Closing pressure 276—414 kPa

Switch 2.7—4.1 bar
40—60 psi
B23—Engine Oil Pressure Sensor Operating pressure 0—2660 kPa

0—26.6 bar
0—385 psi
B25—Steering System Pressure Opening pressure 192—288 kPa

Switch 1.92—2.88 bar
27.9—41.8 psi
B27—Service Brake Accumulator Opening pressure 1875—2261 kPa

Charge Pressure Switch 19.1—22.9 bar
272—328 psi
B28—Torque Convertor Input Speed Resistance 925—1155 Ω

Sensor Gap 0.5—0.8 mm
0.0197—0.0315 in.
Output Signal 4 pulses per revolution
AC Voltage 0.45—7.03 V

092005
PN=545
References
B29—Torque Convertor Output Resistance 925—1155 Ω

Speed Sensor Gap 0.5—0.8 mm
0.0197—0.0315 in.
B30—Internal Clutch Speed Sensor Resistance 925—1155 Ω

Gap 0.5—0.8 mm
0.0197—0.0315 in.
B31—Transmission Output Speed Output Frequency 2 Hz—5 kHz

Sensor Gap 1.0—1.5 mm
0.04—0.06 in.
DC Voltage 20—30 V
B32—Transmission Oil Temperature Resistance 186—246 Ω @ 60°C (140°F)

9015B Sensor 71.2—91.2 Ω @ 90°C (194°F)
20 33—40 Ω @ 120°C (248°F)
56
16.6—20.8 Ω @ 150°C (302°F)
B33—Clutch Cut-Off Sensor Resistance between pins A and B 280—420 Ω Minimum Value
4.28—6.42 kΩ Maximum Value
Resistance between pins A and C 4—6 kΩ
B34—Park Brake Pressure Switch Opening pressure (increasing) 1172—1310 kPa

11.7—13.1 bar
170—190 psi
Closing pressure (decreasing) 931—1137 kPa
9.3—11.4 bar
135—165 psi
B35—Freeze Control Switch Opening temperature (decreasing) -1.4°C

29.5°F
Closing temperature (increasing) 2.2°C
36°F
B40—Brake Light Pressure Switch Closing pressure (increasing) 414 kPa

4.1 bar
60 psi
Opening pressure (decreasing) 276 kPa
2.7 bar
40 psi

092005
PN=546
References
B41—Ride Control Pressure Switch Closing pressure (increasing) 414 kPa

4.1 bar
60 psi
Opening pressure (decreasing) 276 kPa
2.7 bar
40 psi
B45—Analog BHKO/RTC Position Resistance 4—6 kΩ

Sensor
B48—Water-in-Fuel Sensor Resistance 209—231 kΩ
B50—A/C Binary Pressure Switch Opening pressure (high) 2620—2896 kPa (26.2—29 bar)
(380—420 psi)
Closing pressure (high) 1379—2068 kPa (13.8—20.7 bar)
(200—300 psi)
Opening pressure (low) 137.9—227.5 kPa (1.38—2.28 bar)
(20—33 psi)
Closing pressure (low) 158.6—255.1 kPa (1.58—2.55 bar)
(23—37 psi) 9015B
20
57
R1—CAN Termination Node Resistance 120 Ω
R2—CAN Termination Node Resistance 120 Ω
R3—Blower Speed Resistor Low speed resistance (wires A15 1.2 Ω

and A18)
Medium speed resistance (wires A16 0.6 Ω
and A18)
High speed resistance (wires A17 0.4 Ω
and A18)
Y1—Transmission Control Solenoid Resistance 17.1—20.9 Ω

1
Y2—Trans. Control Solenoid 2 Resistance 17.1—20.9 Ω
Y7—Start Aid Solenoid Resistance 2.7—3.3 Ω

092005
PN=547
References
Y13—Differential Lock Solenoid Resistance 25.65—31.35 Ω
Y14—Pilot Enable Solenoid Resistance 25.65—31.35 Ω
Y15—Boom Down Accumulator Resistance 29.79—36.41 Ω

Solenoid
Y16—A/C Compressor Clutch Resistance 12.6—15.4 Ω
Y17—Ride Control Boom Solenoid Resistance 29.79—36.41 Ω
Y18—Ride Control (On/Off) Solenoid Resistance 29.79—36.41 Ω
Y19—Park Brake Release Solenoid Resistance 25.65—31.35 Ω
Y20—Pin Disconnect Solenoid Resistance 25.65—31.35 Ω
Y28—Axle Disconnect Solenoid Resistance 25.65—31.35 Ω
9015B Y34—Ride Control (On/Off) Solenoid Resistance 29.79—36.41 Ω

20
58
Y37—Proportional Fan Solenoid Resistance 21.6—26.4 Ω
Y38—Reverse Fan Solenoid Resistance 29.79—36.41 Ω
OUT1738,0000152 –19–30JUL03–5/5

092005
PN=548
References
Transmission Control Valve Solenoid Check (S.N. 590068— )
9015B
20
59
–19–25NOV03
T193571
Transmission Control Valve Solenoid Check


092005
PN=549
References
Following is a simple test to check electrical operation terminal as shown.

of the transmission hydraulic control unit solenoids:
Specification
1. Disconnect the load center harness-to-transmission Control Valve Solenoid—
Resistance ...................................................................... 15—20 ohms
harness connector (X22). See Transmission
Harness (W10) Component Location (S.N.
3. This check can also be done at the transmission
590068— ) for machine location. (Group 9015B-10.)
control valve connector (X36).
2. Using an ohmmeter, check the resistance between
the common pin terminal (pin V) and each solenoid
OUT1738,0000154 –19–08AUG03–2/2
Clutch Cut-Off Sensor Check and Adjustment

(S.N. 590068— )
1. Turn key switch to on.
2. Press MENU on the monitor to bring up the main

menu.
9015B
20
60 3. Press NEXT twice and then SELECT to enter the
diagnostics menu.
4. Press NEXT twice and then SELECT to view the

transmission sensors.
5. Press NEXT until 7—Clutch Cut-Off V is highlighted

and then press SELECT.
6. With the brake pedals in the up position (not

depressed), verify the clutch cut-off voltage is within
specification.
Specification
Clutch Cut-Off Sensor—Voltage—
Pedal Up .................................................................................... 0.8—1.0 V
NOTE: The clutch cut-off sensor is located under cab on

left brake pedal assembly.
7. If the voltage is not within specification, loosen the

clutch cut-off sensor (B33) cap screws and turn the
clutch cut-off sensor until specification is met.
8. Tighten cap screws.
OUT1738,0000153 –19–30JUL03–1/1

092005
PN=550
References
Boom Height Kickout/Return-to-Carry

Adjustment (S.N. 590068— )
Boom height kickout position can be adjusted from cab

using the following procedure:
2. Push and hold the boom height kickout enable switch

(S39) on the Sealed Switch Module (SSM). Hold until
monitor beeps.
3. Lower boom.
4. Move loader control lever to boom raise detent position

and release.
Boom should raise to the set position.
Return to carry kickout position can be adjusted from the

cab using following procedure:
9015B
20
61
2. Push and hold the return-to-carry enable switch (S40)

on the Sealed Switch Module (SSM). Hold until monitor
beeps.
3. Raise boom.
4. Move loader control lever to boom lower detent

Boom should lower to the set position.
OUT1738,0000156 –19–30JUL03–1/1

092005
PN=551
References
Return-to-Dig Adjustment (S.N. 590068— )
–UN–26JUN00
T131917
9015B
20
62 A—Air Gap Switch-to-Bar C—Cap Screw (2 used) E—Hex Nut F—Switch
B—Adjustable Bar D—Alignment Mark
1. Raise boom adequately to allow clearance for full (medium strength) thread lock and sealer to cap
bucket dump position. screws.
IMPORTANT: The machine hydraulic system must 6. Install cap screws (C) but do not tighten. Adjust bar
be at operating temperature before to align marks on switch bracket and end of bar.
making the adjustment. Cycle the Tighten cap screws.
cylinder through full travel at leaset
4 times to ensure oil in the cylinder Specification
is warm. Adjusting Bar Cap Screw—
Torque.................................................................................... 121 N•m
89.0 lb-ft
2. Move loader control lever to return-to-dig detent
position and release. 7. Loosen hex nuts (E) to switch bracket. Adjust air
gap (A) between switch and adjustable bar (B).
IMPORTANT: Perform this step with the engine Tighten hex nuts.
operating between 1500 - 1700 rpm.
Specification
3. After control lever returns to neutral, scribe a mark Air Gap Between Switch and
(D) on the switch bracket and adjustable bar (B) to Bar—Distance ........................................................................ 5—8 mm
align with each other. 0.197— 0.315 in.
Hex Nut—Torque ..................................................................... 75 N•m
55 lb-ft
4. Position the boom and bucket in the desired
return-to-dig position. Stop engine.
5. Remove cap screws (C), one at a time and remove

old thread lock and sealer. Apply cure primer and
OUT1738,0000158 –19–10FEB05–1/1

092005
PN=552
References
Sensor Circuitry Check (S.N. 590068— )

the sensor is causing a diagnostic trouble code to be
generated. Use the monitor or SERVICE ADVISOR™
application to view codes. See SERVICE ADVISOR
System Computer Connection for information on
connecting to J-Series loaders (S.N. 590068— ).
This procedure will verify if the wiring harness and

controllers are working correctly. This procedure does
not check the sensor.
SERVICE ADVISOR is a trademark of Deere & Company MF82180,0000172 –19–01DEC03–1/3
9015B
Sensor With Two Wires 20
63
Performing Two-Wire Sensor Check:
1. Record and clear diagnostic trouble codes. See

Complete Machine Operational Checkout. (Group
–19–21OCT96
9005-10.)
2. With key switch off, disconnect suspected sensor
wiring harness connector. Connect a jumper wire
between the wires in the harness connector.
T104537
3. Start engine and run for several seconds. Stop engine.
4. Record all diagnostic trouble codes as in Step 1 above.
Results:If a new diagnostic trouble code

(Short-to-Ground” or “Short-to-Power”) appears, a failed
sensor is indicated. (The new diagnostic trouble code was
created when the jumper wire was connected to the
harness connector, proving the harness is OK.)
If a new diagnostic trouble code does not appear, a failed

send the new diagnostic trouble code to the controller.)
Continued on next page MF82180,0000172 –19–01DEC03–2/3

092005
PN=553
References
Sensor With Three Wires
Performing Three Wire Sensor Check
1. Record and clear diagnostic trouble codes. See

Diagnostic Trouble Codes (DTC). (Group 9005-10.)
2. With key switch Off, disconnect the suspected sensor
wiring harness connector. If the original diagnostic
trouble code was “Short to Power” connect a jumper
wire between the sensing wire and the ground wire in
the wiring harness connector.
If the original diagnostic trouble code was “Short to
Ground” connect a jumper wire between the sensing
wire and the power wire in the wiring harness
connector.
3. Start engine and run several seconds. Stop engine.
4. Turn key switch on.
5. Record all diagnostic trouble codes as in Step 1 above.
Results: If a new diagnostic trouble code
–19–21OCT96
(Short-to-Ground” or “Short-to-Power”) appears, a failed
9015B sensor is indicated. (The new diagnostic trouble code was
20 created when the jumper wire was connected to the
64
harness connector, proving the harness is OK.)
T104538
If a new diagnostic trouble code does not appear, a failed
harness or controller is indicated. (The harness cannot Malfunctioning Three-Wire Sensor Test
send the new diagnostic trouble code to the controller.)
MF82180,0000172 –19–01DEC03–3/3

092005
PN=554
References
Diagnostic Trouble Codes—After Machine

Repair (S.N. 590068— )
After repairing the machine, delete all diagnostic trouble

codes from memory. If connected to controller CAN bus
with SERVICE ADVISOR™ application, the DTCs can be
deleted with the “Clear” button under the diagnostics tab.
Or, DTCs can be deleted from the CAN monitor unit as
follows:
Enter the service menu by holding down the MENU button

for 5 seconds. Go to menu 1-3, by first selecting codes (1)
then clear codes (3). Press SELECT to clear all stored
codes. The CMU will verify the codes have been cleared.
See CAN Monitor Unit (CMU) Circuit Theory of Operation
(S.N. 590068— ) for more information. (Group 9015B-20.)
Operate the machine, then check for DTCs to verify that

the problem has been fixed.
9015B
20
65
SERVICE ADVISOR is a trademark of Deere & Company OUT1738,0000157 –19–30JUL03–1/1
Change Back-Up Alarm Volume (S.N.

590068— )
NOTE: The reverse warning alarm is set on high volume

at the factory. It may be necessary to adjust the
volume to meet local regulations.
1. Move wire lead (2) to either HI or LO terminal position

to change reverse warning alarm (1) volume.
–UN–12APR01
2. Leave bar (3) connected to HI and LO terminals to
maintain HI volume. Remove for LO volume.
1—Back-Up Alarm
T140830
2—Wire Lead (M01 Purple)

3—Bar
OUT1738,0000159 –19–30JUL03–1/1

092005
PN=555
References
Remove and Install Pressure Switches (S.N.

590068— )

penetrate the skin causing serious injury.
–UN–23AUG88
Avoid the hazard by relieving pressure before
X9811
fluids.

Any fluid injected into the skin must be
9015B information is available from Deere & Company
20 Medical Department in Moline, Illinois, U.S.A.
66
Before removing any pressure switch, operate all
hydraulic control valves to relieve hydraulic pressure.
With boom raised slightly, turn key switch to on position.

Cycle ride control from off to on. Boom will jump up
unexpectedly if ride control accumulator is energized.
Press and hold pilot enable/boom down switch and move
the control lever into the boom down position and hold for
5 seconds.
Push brake pedal at least 40 times to discharge brake

accumulators.
OUT1738,0000168 –19–09SEP03–1/1

092005
PN=556
References
Replace METRI-PACK™ Connectors (S.N.

590068— )
1. A small locking tab is located inside of the Metri-Pack

connector. Use a small screwdriver (B) to move tab (A)
–UN–01NOV96
outward to the first detent position; the tab will “click.”
A—Tab
B—Screwdriver
T104764B
Metri-Pack is a trademark of Packard Electrical. TX,1674,MM3188 –19–29SEP98–1/3
9015B
2. Slide JDG939 Metri-Pack Extractor Tool (B) into 20
connector body until it is positioned over terminal 67
contact.
3. Gently pull wire out of connector body.
–UN–01NOV96
T104763B
stop is felt.

A—Wire
place. B—Extractor Tool

connector.
TX,1674,MM3188 –19–29SEP98–2/3
7. Use a small screwdriver (B) to move tab (A) inward to

the first detent position; the tab will “click” and lock the
wires in the connector body.
A—Tab
–UN–01NOV96
B—Screwdriver
T104764B
TX,1674,MM3188 –19–29SEP98–3/3

092005
PN=557
References
Install METRI-PACK™ Contact (S.N. 590068—

)
2. Adjust selector (A) on JDG360 Crimper1 for correct

wire size.
–UN–23AUG88
until it stops.
TS117
A—Selector
B—Lock Nut
C—Adjusting Screw
9015B
20
68
Metri-Pack is a trademark of Packard Electric.
1
Included in JDG359 Deutsch Electrical Repair Kit.
TX,1674,MM3189 –19–21OCT98–1/3
IMPORTANT: Select proper size contact “sleeve” or

“pin” to fit connector body.

–UN–23AUG88

TS0134
stop.
A—Contact
B—Cover
7. Release handle and remove contact. C—Lock Nut
D—Adjusting Screw
Continued on next page TX,1674,MM3189 –19–21OCT98–2/3

092005
PN=558
References


procedure.
–UN–23AUG88
barrel.
TS0135
TX,1674,MM3189 –19–21OCT98–3/3
Replace DEUTSCH™ Connectors (S.N.

590068— )
1. Select correct size extractor tool for size of wire to be

removed:
• JDG361 Extractor Tool1 for 12 to 14 gauge wire.

9015B
• JDG362 Extractor Tool1 for 16 to 18 gauge wire. 20
• JDG363 Extractor Tool1 for 20 gauge wire. 69
DEUTSCH is a trademark of the Deutsch Co.
1
Included in JDG359 DEUTSCH Electrical Repair Kit.
Continued on next page ECONN,J –19–03NOV94–1/3

092005
PN=559
References
2. Start correct size extractor tool over wire at handle (A).
3. Slide extractor tool rearward along wire until tool tip

snaps onto wire.
IMPORTANT: Do NOT twist tool when inserting in
–UN–23AUG88
connector.
4. Slide extractor tool along wire into connector body until

it is positioned over terminal contact.
TS0124
5. Pull wire out of connector body, using extractor tool.
A—Extractor Tool Handle
–UN–23AUG88
9015B
TS120
20
70
ECONN,J –19–03NOV94–2/3


stop is felt.
–UN–23AUG88
place.

TS122
connector.
ECONN,J –19–03NOV94–3/3

092005
PN=560
References
Install DEUTSCH™ Contact (S.N. 590068— )
2. Adjust selector (A) on JDG360 Crimper1 for correct

wire size.
–UN–23AUG88
until it stops.
TS117
A—Crimper Selector
B—Lock Nut
C—Adjusting Screw
DEUTSCH is a trademark of the Deutsch Co.
1
Included in JDG359 Deutsch Electrical Repair Kit.
ECONN,W –19–04JUN90–1/4
9015B
IMPORTANT: Select proper size contact “sleeve” or 20
“pin” to fit connector body. 71

–UN–23AUG88
A—Contact
B—Cover
TS0134
C—Lock Nut
D—Adjusting Screw
ECONN,W –19–04JUN90–2/4


stop.
–UN–23AUG88
7. Release handle and remove contact.

TS118
Continued on next page ECONN,W –19–04JUN90–3/4

092005
PN=561
References


procedure.
–UN–23AUG88
barrel.
TS0135
ECONN,W –19–04JUN90–4/4
Replace WEATHER PACK™ Connector (S.N.

590068— )
IMPORTANT: Identify wire color locations with

connector terminal letters.
–UN–23AUG88
1. Open connector body.
9015B
20
72 2. Insert JDG364 Extraction Tool1 over terminal contact in
TS0128
connector body.
3. Hold extractor tool fully seated and pull wire from

connector body.
NOTE: If terminal cannot be removed, insert wire or nail

through extractor tool handle and push terminal
contact from connector.
WEATHER PACK is a trademark of Packard Electric.
1
Included in JT07195A Electrical Repair Kit.
Continued on next page ECONN,O –19–03NOV94–1/2

092005
PN=562
References
IMPORTANT: Carefully spread contact lances to

assure good seating on connector
body.
NOTE: Connector bodies are “keyed” for proper contact

mating. Be sure contacts are in proper alignment.
–UN–23AUG88
4. Push contact into new connector body until fully
seated.
TS0130
place.

connector.
7. Close connector body.
ECONN,O –19–03NOV94–2/2
9015B
Install WEATHER PACK™ Contact (S.N. 20
590068— ) 73
NOTE: Cable seals are color coded for three sizes of

wire:
–UN–23AUG88
• Green - 18 to 20 gauge wire
• Gray - 14 to 16 gauge wire
• Blue - 10 to 12 gauge wire
TS0136
Correct Size Cable
NOTE: Contacts have numbered identification for two

sizes of wire:
• #15 for 14 to 16 gauge wire

–UN–02NOV94
• #19 for 18 to 20 gauge wire
3. Put proper size contact on wire and crimp in place with

a “W” type crimp, using JDG783 Crimping Tool.
TS1623
Strip Insulation
WEATHER PACK is a trademark of Packard Electric. Continued on next page ECONN,AA –19–04JUN90–1/2

092005
PN=563
References
IMPORTANT: Proper contact installation for “sleeve”

(A) and “pin” (B) is shown.
4. Secure cable seal to contact as shown, using JDG783

Crimping Tool.
–UN–02DEC88
A—Sleeve
B—Pin
TS0139
Contact Installation
ECONN,AA –19–04JUN90–2/2
9015B
20
Replace CINCH™ Connectors (S.N. 590068—
74 )
1. Remove extraction tool (1) from the loading side of

connector.
2. Insert blade of extraction tool into locking tabs (2) of

secondary lock (3). Rotate tool away from the
connector to pry one side of the secondary lock out of
the locked position. Repeat this step for the other
locking tab.
NOTE: After unlocking one side of the secondary lock, a

screw driver or similar device may need to be
–UN–29JUN00
used to hold it in the unlocked position while
unlocking the second locking tab.
T132105B
1—Extraction Tool
2—Secondary Lock Locking Tabs
3—Secondary Lock
CINCH is a trademark of the Cinch Co. Continued on next page CED,TX17994,319 –18–09JUN00–1/3

092005
PN=564
References
3. Remove secondary lock (3).
3—Secondary Lock
–UN–29JUN00
T132301B
CED,TX17994,319 –18–09JUN00–2/3
4. Insert pointed side of extraction tool into the contact

cavity so that the flat side of tool faces secondary lock
cavity (4). This will release the primary contact locking
tab.
5. Gently pull wire out of the connector.
–UN–29JUN00
9015B
6. Repair/Replace terminals as necessary using
20
procedure in this group. See Install CINCH Contact 75
(S.N. 590068—).
T132107B
7. Insert contact and wire into connector until it clicks.
8. Install secondary lock.
CED,TX17994,319 –18–09JUN00–3/3

092005
PN=565
References
Install CINCH™ Contact (S.N. 590068— )
9015B
20
–UN–14FEB01
76
T138057
A—Top of Tool D—Wire F—Junior Timer Slot I—Wire Tab
B—Contact Support E—Micro Timer Slot G—Contact J—Insulation Tab
C—Locator
1. Hold JDG708 crimping tool so that the tool is facing 3. Hold the contact in position and squeeze the tool
you as shown (left side of graphic). Squeeze tool handles together until ratchet engages sufficiently to
handles together and allow them to open fully. hold the contact in position. Do NOT deform wire
and insulation tabs (I and J).
IMPORTANT: Make sure that both sides of the
insulation barrel are started evenly 4. Insert stripped wire into contact insulation and wire
into the crimping section. Do NOT tabs until it is butted against locator (C).
attempt to crimp an improperly
positioned contact. 5. Hold the wire in place. Squeeze tool handles
together until ratchet releases. Allow tool handles to
2. Position the contact so that the mating end of the open and remove crimped contact.
contact (G) is on the locator side of the tool (C).
Wire and insulation tabs (I and J) should point to 6. Install contact into connector. See Replace CINCH
top of tool (A). Butt wire tab (I) against the movable Connectors (S.N. 590068— ). (Group 9015—20.)
locator (C).
CINCH is a trademark of the Cinch Co. DW70185,0000002 –19–13DEC04–1/1

092005
PN=566
References
Repair 32 and 48 Way CINCH™ Connectors

(S.N. 590068— )
CINCH is a trademark of the Cinch Co. OUO6045,00002FC –19–10SEP03–1/5
1. Press tab (A) and rotate locking cam (B) 90° to

disconnect connector from flexbox.
2. Move cover locks (C) slightly outward with a small

screwdriver.
–UN–10SEP03
3. Remove cover (D) away from wires.
A—Tab
RXA0070459
B—Locking Cam
C—Cover Locks
D—Cover
9015B
20
77
–UN–10SEP03
RXA0070462
–UN–10SEP03
RXA0070463
Continued on next page OUO6045,00002FC –19–10SEP03–2/5

092005
PN=567
References
4. Pull terminal lock (A) out as far as it will go, but do not
force its removal.
A—Terminal Lock
–UN–10SEP03
RXA0070464
OUO6045,00002FC –19–10SEP03–3/5
NOTE: JDG1725 Terminal Extractor Tool has two

different sizes of pins, 0.6 for smaller 20 gauge
holes (A), and 1.5 for larger 16 and 18 gauge
holes (B).
–UN–10SEP03
5. Insert JDG1725 Terminal Extractor Tool into holes (C)
next to terminal opening (D) to unlock terminal.
9015B
20
78 6. Pull wire and terminal (E) from connector body.
RXA0070471
A—20 Gauge Holes
B—16 & 18 Gauge Holes
C—Holes
D—Terminal Hole
E—Terminal
–UN–10SEP03
RXA0070472
–UN–10SEP03
RXA0070473
Continued on next page OUO6045,00002FC –19–10SEP03–4/5

092005
PN=568
References
7. Remove old terminal and strip 4.85 mm (0.191 in.) of

insulation from wire.
8. Grip JDG1727 Terminal Crimping Tool (A) securely,

and squeeze ratcheting mechanism until it bottoms out.
–UN–10SEP03
Then allow it to open completely
9. With tool in ready position (open handle), open

terminal receptacle (B).
RXA0070479
10. Insert terminal (C) into proper wire gauge window,
crimp wings facing up.
11. Close terminal receptacle (B).
12. Squeeze handle until two clicks are heard.
13. Insert stripped wire (D) into terminal.
–UN–10SEP03
14. Hold wire stationary and squeeze tool together until
ratchet releases.
9015B
RXA0070480
15. Remove terminated wire from tool. 20
79
16. Push terminal into connector body until fully seated.

Pull on wire slightly to ensure terminal is locked in
position.
17. Push terminal lock closed.
18. Install cover.
–UN–10SEP03
19. Install connector to controller and close connector
body locking cam.
RXA0070481
A—CINCH Terminal Crimping Tool
B—Terminal Receptacle
C—Terminal
D—Wire
OUO6045,00002FC –19–10SEP03–5/5

092005
PN=569
References
Remove Connector Body from Blade

Terminals (S.N. 590068— )
1. Depress locking tang (A) on terminal, using a small

screw driver. Slide connector body off.
–UN–23AUG88
2. Be sure to bend locking tang back to its original
position (B) before installing connector body.
RW4218
DX,ECONN,V1 –19–02NOV94–1/1
Engine Control Unit (ECU) Remove and

Install (S.N. 590068— )
1. Turn battery disconnect to the OFF position.
2. Loosen cap screws (1) to gain access to the load
–UN–27AUG03
center compartment. The ECU (2) is mounted to the
9015B
20 top side of the compartment.
80
T194448A
1—Load Center Cover Cap Screw (4 used)
2—Engine Control Unit (ECU)
–UN–27AUG03
T194449A
Continued on next page OUT1738,000015B –19–30JUL03–1/2

092005
PN=570
References
3. Loosen cap screws (3) and remove ECU connectors.
4. Remove mounting screws (4) to remove control unit.
5. Install new controller and tighten mounting cap screws.
–UN–08SEP03
IMPORTANT: The ECU connectors need to be torqued
to specification to prevent connection
problems and damage to the connector.
T194623A
6. Install ECU connectors and tighten cap screws to
specification.
ECU Connectors
Specification
ECU Connector Screw—Torque ....................................... 1.69—2.26 N•m
1.25—1.66 lb-ft
7. Close load center doors and tighten cap screws.
8. Turn battery disconnect to the on position.
–UN–08SEP03
9. Reset options in the monitor. See CAN Monitor Unit
9015B
(CMU) Circuit Theory of Operation (S.N. 590068— ). 20
(Group 9015B-15.) 81
T194451A
3—ECU Connector Cap Screw (2 used)
4—Engine Control Unit (ECU) Mounting Screw (4 ECU Mounting Cap Screws
used)
OUT1738,000015B –19–30JUL03–2/2

092005
PN=571
References
Flex Load Controller (FLC) Remove and

Install (S.N. 590068— )
–UN–27AUG03
center compartment. The FLC (2) is mounted on the
back wall of the compartment.
3. Remove connectors (3) by pressing in locking tab (4)
T194448A
and rotate retainer (5) counterclockwise to release.
4. Remove mounting cap screws (6) to remove control

unit.
6. Install FLC connectors.
–UN–28AUG03
9015B 8. Turn battery disconnect to the ON position.

20
T194481A
82
9. Reconfigure the electronic controllers See Electronic
Controller Reconfiguration (S.N. 590068—). (Group
9015B-20.)
10. Reset machine options in the monitor. See CAN

Monitor Unit (CMU) Circuit Theory of Operation (S.N.
590068— ). (Group 9015B-15.)
–UN–28AUG03
T194482A
OUT1738,000015C –19–10DEC04–1/1

092005
PN=572
References
Transmission Control Unit (TCU) Remove

and Install (S.N. 590068— )
–UN–27AUG03
center compartment. The TCU (2) is mounted to the
back side of the compartment.
3. Pull up on connector lock (3) and remove TCU
T194448A
connector.
4. Remove mounting cap screws to remove control unit.
6. Install TCU connector by pushing connector lock down.
–UN–05SEP03
8. Turn battery disconnect to the ON position.
9015B
20
T194605A
9. Reconfigure the electronic controllers. See Electronic
83
9015B-20.)
1—Load Center Cover Cap Screw (4 used)
10. Reset machine options in the monitor. See CAN 2—Transmission Control Unit (TCU)
Monitor Unit (CMU) Circuit Theory of Operation (S.N. 3—TCU Connector Lock
590068— ). (Group 9015B-15.)
OUT1738,000015D –19–10DEC04–1/1

092005
PN=573
References
Sealed Switch Module (SSM) Remove and

Install (S.N. 590068— )
1. Turn key switch to the OFF position.
2. Remove nuts (1) on backside of module.
–UN–28AUG03
3. Pull module up and disconnect harness connector (2).
4. Install new module and tighten mounting nuts.
T194491A
–UN–02SEP03
9015B
20
T194492A
84
OUT1738,000015E –19–30JUL03–1/1

092005
PN=574
References
CAN Monitor Unit (CMU) Remove and Install

(S.N. 590068— )
2. Remove monitor mounting screws (1).
3. Pull monitor forward and disconnect harness connector

(2).
–UN–09OCT03
4. Install new monitor and tighten mounting screws.
5. Turn battery disconnect to the ON position.
T195499A
6. Reprogram CMU. See Reprogram CAN Monitor Unit
(CMU) (S.N. 590068— ). (Group 9015B-20.)
7. Reconfigure the electronic controllers. See Electronic

9015B-20.)
8. Reset machine options in the monitor. See CAN 9015B

20
Monitor Unit Circuit (CMU) Theory of Operation (S.N.
85
–UN–09OCT03
560068—). Group9015B-15.)
1—CAN Monitor Unit (CMU) Mounting Screw (4 used)

2—CMU Connector
T195500A
OUT1738,000015F –19–10DEC04–1/1
Reprogram CAN Monitor Unit (CMU) S.N.

590068—)
When the CAN Monitor Unit (CMU) is replaced, it must be

reprogrammed. Reprogramming is done using the
following procedure.
NOTE: When the CMU is first powered on after

replacement, the CMU will display 544 as the
model. This is before the auto configuration has
run.
1. Turn the key switch on. After the CMU initially starts,
the CMU will compare information between the FLC
and TCU. If the information is valid, that information
will be stored in the CMU memory.
Continued on next page OUT1738,000016C –19–03NOV03–1/3

092005
PN=575
References
2. The set hours screen will be displayed. Press NEXT to

choose between NO or YES. Set Hours 1/2
a. If NO is selected, the monitor will operate as
1-No
normal. The monitor will start with the set hours 2-Yes
screen a total of 5 times. If the hours are not set on
–19–04NOV03
the fifth time, the CMU will acquire the machine
hours operated since the monitor was installed.
b. If YES is selected, the set hour meter screen will be
T196067
displayed. If the hour meter was not set on the first
attempt, the set hour meter screen will default with
the hours accrued since the monitor installation.
OUT1738,000016C –19–03NOV03–2/3
9015B
20 3. To set the hours, press BACK to select the next digit to
86 the left, press NEXT to increase, press MENU to exit,
and press SELECT to store the hour meter reading. Set Hour Meter
4. Enter the service menu and verify the tire size is BACK to left
correct. See CAN Monitor Unit (CMU) Theory of
–19–04NOV03
Operation. (Group 9015-15.) NEXT to increase
5. Verify that all settings are monitor settings are correct. SELECT to store
0 0 0 0 0.0
T196068
NOTE: If the CMU is being replaced along with the TCU
or FLC, the model number will have to be set
using the Service Menu and the serial number will
have to be set using SERVICE ADVISOR™.
SERVICE ADVISOR is a trademark of Deere & Company OUT1738,000016C –19–03NOV03–3/3

092005
PN=576
References
Electronic Controller Reconfiguration (S.N.

590068 —)
IMPORTANT: Whenever a CAN monitor unit (CMU), a

flex load controller (FLC), or a
transmission control unit (TCU) is
replaced, the controllers must be
reconfigured. The reconfiguration
procedure is performed in the Service
Menu.
IMPORTANT: If the CAN monitor unit (CMU) is

replaced, the CMU will request to be
programmed the first time the key
switch is turned to On. Reprogram the
CMU before proceeding with
reconfiguration. See Reprogram CAN
Monitor Unit (CMU) See procedure in
Group 9015 -20)
IMPORTANT: The FNR lever or the FNR switch

located on the pilot controller must be 9015B
20
in neutral position and the park brake
87
must be applied in order for the
reconfiguration to be successful.
NOTE: The park brake light on the CMU indicates if the

park brake is applied.
1. Turn the key switch to On. Allow the CAN monitor unit
(CMU) to perform the bulb check. The bulb check will
take 5 seconds to complete.
2. If the CAN monitor unit (CMU) was replaced, complete

the CMU reprogramming before performing a
reconfiguration.
3. To reconfigure the machine access the service menu.

Press and hold the MENU button for 5-seconds. See
CAN Monitor Unit (CMU) Theory of Operation (S.N.
590068 —)
4. From the CMU Main Menu, select Machine Config (5)

(Machine Configuration)
Continued on next page DW70185,000000C –19–31JAN05–1/3

092005
PN=577
References
IMPORTANT: When reconfiguring a machine, the

enabled options will be reset. If
possible, before proceeding with the
reconfiguration procedure, record the
current machine configuration from
Enable Options menu.
5. From the Machine Config menu option select Machine

Model (5-1).
IMPORTANT: In some instances, the model number in

the display will match the model
number of the machine. If so, you still
need to highlight the model number and
press and hold the SELECT button on
the CMU until you hear an audible
“beep.” The “beep” along with the
check mark next to the model number
indicate the FLC has been properly
configured to the current machine
model.
9015B
20 6. Using the NEXT button, scroll through the model list
88
until the correct machine model is highlighted. Then,
press the SELECT button. An audible beep and a
check mark will appear beside the machine model to
confirm the reconfiguration was successful.
7. Press the BACK button to return to the Machine Config

menu
8. From the Machine Config menu select Tire Size (5-2).

Match the tire size of the machine with tire size option
from the menu.
IMPORTANT: During reconfiguration tire size will

default to the base tire size associated
with each machine model.
9. Press the BACK button to return to the Machine Config

menu
10. From the Machine Config menu select Enable

Options (5-3). Enable the options unique to that
machine, if any. Use the NEXT button to highlight the
option, then press the SELECT button to enable the
feature.
Continued on next page DW70185,000000C –19–31JAN05–2/3

092005
PN=578
References
11. Turn key to Off. When the key is turn back On, the
controllers will be rebooted to their proper
configuration.
NOTE: Turning the key switch to Off will also close the
Service menu of the CMU.
DW70185,000000C –19–31JAN05–3/3
9015B
20
89

092005
PN=579
References
9015B
20
90

092005
PN=580
Section 9020
Power Train
Contents
Page Page
Group 05—Theory Of Operation Converter—In Pressure Test . . . . . . . . . . . .9020-25-19

TEAMMATE™ Axles . . . . . . . . . . . . . . . . . . .9020-05-1 Converter—Out Pressure Test . . . . . . . . . .9020-25-21
Transmission Clutch Engagement And Converter Relief Pressure Test . . . . . . . . . .9020-25-24
Solenoids Activated . . . . . . . . . . . . . . . . . .9020-05-1 Converter—Out Flow Test. . . . . . . . . . . . . .9020-25-26
Power Train Components . . . . . . . . . . . . . . .9020-05-2 Torque Converter Stall Speed Test . . . . . . .9020-25-29
Transmission Operation . . . . . . . . . . . . . . . .9020-05-4 Transmission Oil Cooler Thermal Bypass
Transmission Operation—First Gear Valve Temperature Test . . . . . . . . . . . . .9020-25-30
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-6 Transmission Oil Cooler Thermal Bypass
Transmission Control Valve Components . . .9020-05-9 Valve Pressure Test . . . . . . . . . . . . . . . .9020-25-32
Transmission Clutch Modulation . . . . . . . . .9020-05-12 Transmission Oil Cooler Restriction Test. . .9020-25-34
Thermal Bypass Valve Operation . . . . . . . .9020-05-14 Axle Circulation Dual Pump Flow and
Axle Circulation Motor and Dual Pumps . . .9020-05-15 Temperature Tests . . . . . . . . . . . . . . . . .9020-25-36
Park Brake Operation . . . . . . . . . . . . . . . . .9020-05-16 Axle Circulation Motor Flow Test. . . . . . . . .9020-25-38
Axle Breather Test . . . . . . . . . . . . . . . . . . .9020-25-39
Group 15—Diagnostic Information Axle Circulation Pump Inlet Suction
Transmission Control Circuit—First Check . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-40
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-15-2
Power Train Component Location . . . . . . . . .9020-15-4 9020
Diagnose Transmission System
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9020-15-6
Diagnose Differential And Axle
Malfunctions . . . . . . . . . . . . . . . . . . . . . .9020-15-20
Diagnose Service Brake Malfunctions . . . . .9020-15-26
Diagnose Drive Line Malfunctions . . . . . . . .9020-15-28
Diagnose Park Brake Malfunctions . . . . . . .9020-15-29
External Service Brake Inspection . . . . . . . . .9020-20-1
Transmission Control Unit (TCU)—
Electronic Clutch Adjustment (S.N. —
590067) . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-3
Transmission Control Unit (TCU)—
Electronic Clutch Calibration (S.N. 590068—
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-20-7
Group 25—Tests
Transmission Oil Warm-Up Procedure . . . . .9020-25-1
Driveline Bearing—Park Brake Pressure
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-2
Driveline Bearing—Park Brake Drag Test . . .9020-25-4
Transmission Pump Flow Test . . . . . . . . . . .9020-25-6
Transmission System Pressure Test . . . . . . .9020-25-8
Transmission Clutch Pressure Test . . . . . . .9020-25-10
Transmission Element Leakage Test. . . . . .9020-25-13
Lube Pressure Test. . . . . . . . . . . . . . . . . . .9020-25-15
Differential Lock Pressure Test . . . . . . . . . .9020-25-17

092005
PN=1
Contents
9020

092005
PN=2
Group 05
Theory Of Operation
TEAMMATE™ Axles
For additional information on TEAMMATE™ axles and

components, see the following Component Technical
Manual (CTM).
• See TeamMate™ III 1000, 1200, and 1400 Series

Inboard Planetary Axles. (CTM150.)
TEAMMATE is a trademark of Deere & Company BT40170,00000A8 –19–12DEC03–1/1
Transmission Clutch Engagement And

Solenoids Activated
Transmission Clutch Engagement and Solenoids Activated
Directional Pack Engaged Speed Pack Engaged
Lo-Range Forward Hi-Range Forward Reverse 1st 2nd 3rd
(KV) (K4) (KR) (K1) (K2) (K3)
Gear
N1
N2
N3
N4 9020
F1 Solenoid Y5 Solenoid Y3 05
1
F2 Solenoid Y5 Solenoid Y6
R1 Solenoid Y2 Solenoid Y3
For theory of operation, see Transmission Operation in

this group.
This table shows the clutch packs that are engaged with
their corresponding solenoids for a selected gear. For
example, in first forward (F1) solenoids Y5 and Y3 are
energized to engage low-range forward direction clutch
pack (KV) and first speed clutch (K1). Notice in the neutral
gears no clutch packs are engaged.
BT40170,00000AA –19–12DEC03–1/1

092005
PN=583
Theory Of Operation
Power Train Components
NOTE: For location of components, see Power Train

Component Location. (Group 9020-15.)
The power train consists of the following components:
• Drive dampener
• Drive shaft
• Torque converter
• Transmission
• Front and rear drive shafts
• Park brake
• Front and rear axles
Engine power is transmitted to the transmission torque

converter by a drive dampener on the engine flywheel and
a universal joint drive shaft.
A single stage torque converter drives a hydraulically

engaged four speed forward, three speed reverse,
countershaft type power shift transmission.
A multiple wet disk park brake is located in the front drive

line. The park brake also functions as a bearing support
for the front driveline.
9020
05 The transmission outputs through universal joints and
2 through two telescoping drive shaft assemblies. The front
axle is mounted directly to the loader frame. The front
axle may be equipped with either a standard differential,
hydraulic differential lock, or a limited slip differential.
The rear axle is mounted on an oscillating pivot. The rear

axle can be equipped with the same differential options as
the front.
BT40170,00000B1 –19–12DEC03–1/1

092005
PN=584
Theory Of Operation
9020
05
3

092005
PN=585
Theory Of Operation
Transmission Operation
9020
05
4
–19–19FEB97
T106975
Continued on next page BT40170,00000AB –19–12DEC03–1/3

092005
PN=586
Theory Of Operation
A—Turbine E—Transmission Pump I—Low Range Drive Gear L—Stator

B—Engine Speed Sensor F—Sealing Ring J—Turbine Shaft M—Torque Converter
C—Impeller G—Impeller Shaft K—Vent Components
D—Oil Seal H—High Range Drive Gear
BT40170,00000AB –19–12DEC03–2/3
INPUT
A
REVERSE
C LOW RANGE
D 2ND SPEED HIGH RANGE
L
1ST SPEED
E 3RD SPEED
I
OUTPUT 9020
–19–19FEB97
05
5
TRANSMISSION GEAR PATTERN
T106954
T106954
(VIEWED FROM CONTROL VALVE SIDE)
A—Reverse D—Second Speed J—High Range I—Output

C—Low Range E—Third Speed L—First Speed
The transmission is a hydraulically engaged four speed (K4) hubs. The reverse clutch (KR), high range forward
forward, three speed reverse countershaft-type, clutch (K4) and second speed clutch (K2) output gears
powershift transmission. are in constant mesh. As are the first speed clutch
(K1) hub gear and the third speed clutch (K3) output
Six clutch packs provide four forward and three gear.
reverse speeds. Two clutch packs, have to be
engaged for movement: One directional clutch pack, The torque converter is a single stage, single phase
either low-range forward (KV), high-range forward (K4) torque converter.
or reverse and one speed clutch pack, either first (K1),
second (K2) or third (K3). (See Transmission Clutch Main pressure oil is routed through a passage in the
Engagement And Solenoids Activated chart for countershaft to engage the clutches.
solenoid/clutch pack combinations.) The torque
converter supplies torque to two drive gears which are Lube oil is routed to each clutch shaft through a
in constant mesh with the forward low-range (KV), manifold plate mounted between the torque converter
reverse clutch (KR) and the high range froward clutch and the transmission case.
BT40170,00000AB –19–12DEC03–3/3

092005
PN=587
Theory Of Operation
Transmission Operation—First Gear Forward
9020
05
6
–19–19FEB97
T106951
Continued on next page TX,9020,ME429 –19–10AUG96–1/3

092005
PN=588
Theory Of Operation
A—Reverse Clutch (KR) F—Front Output Flange I—Output Shaft M—Transmission Pump
B—Hydraulic Pump Drive G—Rear Output Flange J—High Range (K4) FWD N—Drive Flange
C—Low Range (KV) FWD H—Transmission and Torque Clutch O—Torque Converter
Clutch Engaged Converter—First Gear K—Converter Relief Valve P—Engine Speed Sensor
D—Second Speed (K2) Clutch Forward L—First Speed (K1) Clutch
E—Third Speed Clutch (K3) Engaged
9020
05
7

092005
PN=589
Theory Of Operation
INPUT
A
C REVERSE
LOW RANGE
(ENGAGED)
J
D
HIGH RANGE
2ND SPEED
L
E 1ST SPEED
3RD SPEED (ENGAGED)
I
OUTPUT
–19–19FEB97
T106956
T106956
POWER FLOW - 1ST FORWARD
9020 A—Reverse D—Second Speed J—High Range I—Output

05 C—Low Range (engaged) E—Third Speed L—First Speed (engaged)
8
With the transmission in first forward, the low-range Power flow from the low range clutch output gear is
forward clutch (C) and the first speed clutch (L) are connected through the second speed output gear, the
engaged. high range forward output gears to the first speed
clutch drum and gear.
Main pressure oil is routed through the drilled passage
in the countershaft to the low-range-forward and first Power flow continues out the first speed hub gear to
speed clutches. This causes the pistons to extend, the third speed output gear and finally on to the output
compressing the plates and disks causing both shaft gear.
clutches to rotate as a unit through the upper clutch
drum.
The torque converter supplies torque to a drive gear

which meshes with the gear on the low-range forward
clutch hub (C).
TX,9020,ME429 –19–10AUG96–3/3

092005
PN=590
Theory Of Operation
Transmission Control Valve Components
A B PRESSURE
REDUCING
PRESSURE VALVE
REGULATING
VALVE
SOLENOID
(6) H
Y6 Y1 C
CONNECTOR
Y5 Y2
D COVER
G
MODULATION
CIRCUIT Y4 Y3
–19–19FEB97
HOUSING F E VALVE
BLOCK
T107153
T107153
I TRANSMISSION CONTROL VALVE 9020
05
Transmission Control Valve 9
A—Pressure Regulating Valve D—Cover F—Housing H—Solenoid (6 used)

B—Pressure Reducing Valve E—Valve Block G—Modulation Circuit I—Transmission Control Valve
C—Connector
Continued on next page BT40170,00000AC –19–12DEC03–1/4

092005
PN=591
Theory Of Operation
VALVE BODY A B PRESSURE C PRESSURE

REGULATING REDUCING CONNECTOR D
VALVE VALVE
E INTERMEDIATE
PLATE
G PLATE F CHANNEL PLATE

H MAIN PRESSURE OIL J REDUCED PRESSURE OIL
–19–19FEB97
I RETURN OIL K CONVERTER PRESSURE OIL
T107151
T107151
L TRANSMISSION PRESSURE REGULATING CIRCUIT
Transmission Pressure Regulating Circuit
9020
05 A—Valve Body E—Intermediate Plate H—Main Pressure Oil K—Converter Pressure Oil
10 B—Pressure Regulating Valve F—Channel Plate I—Return Oil L—Transmission Pressure
C—Pressure Reducing Valve G—Plate J—Reduced Pressure Oil Regulating Circuit
D—Connector

092005
PN=592
Theory Of Operation
B DAMPER VALVE
PROPORTIONAL
SOLENOID VALVE A
C BOOSTER
VALVE
Y2
D INTERMEDIATE
PLATE
E CHANNEL
PLATE H PLATE
F TO CLUTCH
G TRANSMISSION
CASE
I MAIN PRESSURE OIL
–19–28AUG96
J MODULATED PRESSURE
TO CLUTCH
K REDUCED PRESSURE FROM
PROPORTIONAL VALVE
T102739
T102739 M MODULATION CIRCUIT L RETURN OIL
Modulation Circuit 9020
05
A—Proportional Solenoid D—Intermediate Plate H—Plate K—Reduced Pressure From 11
Valve E—Channel Plate I—Main Pressure Oil Proportional Valve
B—Damper Valve F—To Clutch J—Modulated Pressure To L—Return Oil
C—Booster Valve G—Transmission Case Clutch M—Modulation Circuit
NOTE: For overall system operation see Transmission • Pressure reducing valve
Control Circuit—First Forward. (Group • Six dampening valves
9020-15.) • Six booster valves
• Six proportional solenoid valves
The transmission control valve assembly regulates the
hydraulic control circuit of the transmission. The control The pressure regulating valve is a spring-loaded spool
valve receives electrical signals from the transmission valve which regulates main pressure oil by controlling
controller to energize the proportional solenoids which flow into the control circuit. Excess oil from the control
direct oil to move the booster valves. When the circuit flows to the torque converter.
booster valves are shifted against the spring, oil
pressure begins to start modulation and fill the Main pressure oil flows to the solenoid pressure
oncoming pack. reducing valve. The pressure reducing valve provides
a constant oil pressure to the proportional solenoids
The transmission control valve contains: and is not affected by shift modulation. The solenoid
pressure reducing valve is not adjustable.
• Pressure regulating valve

092005
PN=593
Theory Of Operation
The six proportional solenoid valves direct oil to the • Y6 solenoid valve engages the second speed
booster valves to provide machine direction, speed forward booster valve.
selection and shift modulation. The transmission
controller sends a varying electrical signal to the All booster valves and springs are identical.
proportional solenoids which controls the speed of
clutch engagement during a shift. All of the The dampening valves act as an accumulator in the
proportional solenoid valves are identical. control circuit. Any pressure spikes will be absorbed by
the dampening valve which allows for smooth and
• Y1 solenoid valve engages the high-range forward quiet operation of the booster valves. All dampening
booster valve. valves and springs are identical.
• Y2 solenoid valve engages the reverse booster
valve. Two clutch packs have to be engaged for the machine
• Y3 solenoid valve engages the first speed booster to move. One directional clutch pack, either low-range
valve. forward, high-range forward or reverse and one speed
• Y4 solenoid valve engages the third speed booster clutch pack, either first, second or third.
valve.
• Y5 solenoid valve engages the low-range forward
booster valve.
BT40170,00000AC –19–12DEC03–4/4
9020
05
12
Transmission Clutch Modulation
The transmission controller will vary the clutch modulation

according to a number of speed and load factors.
Therefore, if clutch modulation is checked in a test
condition with the machine stopped and the transmission
in stalled condition, the clutch modulation will be different
than normal operation.
The proportional solenoids control the rate of engagement

and disengagement of clutches. This provides the
optimum timing of the modulating clutches. This provides
a smooth shift between each gear under all operating
conditions.
In neutral-to-first forward shift only, low range forward

clutch is modulated. The same is true for the reverse shift,
only the reverse clutch is modulated. In all of the speed
changes in forward and reverse only the engaging clutch
is modulated.
BT40170,00000AD –19–12DEC03–1/1

092005
PN=594
Theory Of Operation
9020
05
13

092005
PN=595
Theory Of Operation
Thermal Bypass Valve Operation
C
D
H
C TO C G
LUBE F
FROM
D D
COOLER
9020
05
14 SEAT B
H SPRING
VALVE A
FROM
E E
CONVERTER
I BYPASS J COOLING
THERMOSTAT G
F TO
–19–20JAN98
F
COOLER
K LUBE/CONVERTER-OUT FLOW
L TO COOLER (VALVE CLOSED)
T7799BX
TXC7799BX M THERMAL BYPASS VALVE FLOW
Continued on next page BT40170,00000AE –19–12DEC03–1/2

092005
PN=596
Theory Of Operation
A—Valve E—From Converter I—Bypass L—To Cooler (valve closed)

B—Seat F—To Cooler J—Cooling Flow
C—To Lube G—Thermostat K—Lube/Converter-Out Flow M—Thermal Bypass Valve
D—From Cooler H—Spring
The thermal bypass valve is used to maintain the avoiding thermal shock. Converter outlet flow enters
transmission oil temperature at a level which provides passage (E) and flows through the valve (A) to lube
optimum torque converter performance. (C).
The valve contains a standard automotive-type At higher temperatures, the thermostat (G) begins to
thermostat element connected to a hollow valve spool. open, allowing flow out of passage (F) to the
transmission oil cooler. The thermostat will go to the
The valve is designed to bypass the transmission oil full open position, forcing the valve closed against the
cooler at low temperatures. Passages in the valve seat (B). The spring loaded seat will act as a pressure
allow a small amount of oil to flow to the cooler at low relief valve in the event cooler flow is blocked.
temperatures. This allows the cooler to warm slowly
BT40170,00000AE –19–12DEC03–2/2
Axle Circulation Motor and Dual Pumps
For more axle circulation motor and dual pump

information, see Power Train Component Location. (Group
9020-15.)
9020
The axle oil circulation system is designed to circulate oil 05
15
from the sump of each axle over the braking elements.
This oil flow helps keep the brakes and axle hydraulic oil
from overheating.
The gear type circulation motor and dual pump assembly

(10) has a through shaft and integral flow control valve.
The circulation motor and dual pump assembly is serviced
as a complete assembly with the exception of the flow
control valve. The flow control valve is not adjustable.
The axle circulation motor is driven by hydraulic oil from

the main hydraulic system and drives two axle pumps.
The axles are closed loop systems, so each axle requires
a separate pump. Axle oil and main hydraulic oil never
mix. The fluid is drawn through an inlet suction screen in
the bottom of the differential housing and returned to the
top of axle where it is distributed to the brakes. Oil flows
through the brake and back into the sump.
Axle oil coolers are available as a option for extreme duty

applications and are located within the cooling package.
BT40170,00000AF –19–12DEC03–1/1

092005
PN=597
Theory Of Operation
Park Brake Operation
BREATHER C
PISTON D
SPRING (46) B
SEAL A
9020
05
16
E TRANSMISSION
PRESSURE OIL
F LUBRICATION OIL
–19–28AUG96
T101751
T101751 G PARK BRAKE ASSEMBLY
A—Seal C—Breather E—Transmission Pressure Oil G—Park Brake Assembly

B—Spring (46 used) D—Piston F—Lubrication Oil
Continued on next page BT40170,00000B0 –19–12DEC03–1/3

092005
PN=598
Theory Of Operation
I TRANSMISSION PRESSURE OIL

J RETURN OIL
SOLENOID ASS'Y B
(DE-ENERGIZED)
CHECK A
VALVE
C ORIFICE
D PRESS.
SW.
E TO PARK
BRAKE
9020
05
17
–19–28AUG96
G INLET FROM F RETURN TO
TRANS TRANS
T101936
T101936 H PARK BRAKE SOLENOID – PARK BRAKE "ON"
A—Check Valve C—Orifice F—Return To Transmission H—Park Brake Solenoid—Park

B—Solenoid Assembly D—Pressure Switch G—Inlet From Transmission Brake ON
(de-energized) E—To Park Brake
The park brake is a multiple wet disk type, spring park brake also serves as the front drive line support
applied hydraulically released mechanical device. The bearing.
Continued on next page BT40170,00000B0 –19–12DEC03–2/3

092005
PN=599
Theory Of Operation
The separator plates are held stationary with the brake solenoid (H) and route oil flow to the transmission
housing. The brake disks are splined to the shaft. sump. The park brake will remain applied.
When the park brake is released the park brake
solenoid valve is energized and oil pressure from the When the park brake switch is moved to the ON
transmission pump enters the cavity behind the piston position or the machine is shut off the park brake
moving it to the right against the spring retainer which solenoid valve is de-energized. The park brake
compresses the springs. This allows the disks to rotate solenoid valve (H) will move to open allow oil inside
with the shaft and the drive line is free to turn. the park brake piston cavity to return to the
transmission. The springs force the spring retainer and
The TCU controls the operation of the park brake. To piston to the left compressing the plates against the
released the park brake the engine must be running. disks. This locks the drive line to the brake housing to
The TCU receives confirmation the engine is running apply the park brake.
from the input signal off the torque converter input
speed sensor. The TCU needs to read 300 RPM or If the engine should stop running, as long as the key
more as confirmation the engine is running. This data switch remains in the ON position the park brake
is NOT displayed as the tachometer reading of the solenoid (H) will remain energized. The check valve
CMU. The RPM data from the torque converter input (A) will seat to temporarily maintain oil pressure inside
speed sensor can be viewed from the CMU menu. the park brake and keep the brake released. When the
machine slows to a ground speed of approximately 1/2
With the engine running move the park brake release mph, the TCU will de-energize the park brake solenoid
switch to the momentary or OFF position. This will (H) and allow the oil in the park brake to be sent to the
energize the park brake solenoid valve (H). The transmission sump. This will apply the park brake.
solenoid will block the return path to the transmission
sump and direct the transmission oil to the park brake. The park brake can be released by using a
At the same time the transmission oil must open park hand-operated hydraulic pump in a machine down
brake pressure switch (D) immediately. If the park situation. For correct procedure see Towing Procedure.
brake pressure switch (D) responds slowly or fails to (Operator’s Manual.)
9020
05 open, the TCU will de-energize the park brake release
18
BT40170,00000B0 –19–12DEC03–3/3

092005
PN=600
Group 15
9020
15
1

092005
PN=601
Transmission Control Circuit—First Forward

T192490 –19–19DEC03
1 KR 2 K4 HIGH 3 K1 4 K3 5 KV LOW 6 K2 13 PARK

REVERSE RANGE 1ST SPEED 3RD SPEED RANGE 2ND SPEED BRAKE
CLUTCH FORWARD CLUTCH CLUTCH FORWARD CLUTCH
CLUTCH CLUTCH
14 PARK
BRAKE
7 8 9 10 11 12
SWITCH
TRANSMISSION
TEMPERATURE
SENSOR 18 T
15
PARK
17 SYSTEM 19 SYSTEM PRESSURE BRAKE
16 TRANSMISSION 21 TORQUE PRESSURE TEST PORT SOLENOID
CONTROL VAVLE CONVERTER REGULATING
INLET VALVE
PRESSURE
24 TORQUE TEST PORT
CONVERTER
20 FILTER
OUTLET 25 RELIEF
PRESSURE
TORQUE 23 TORQUE VALVE
TEST PORT
CONVERTER CONVERTER
BACK PRESSURE 22 TORQUE
VALVE CONVERTER
RELIEF
VALVE 29 TRANSMISSION
26 THERMAL PUMP
RELIEF 28 SYSTEM
BYPASS PRESSURE
31 MAIN PRESSURE VALVE RELIEF
VALVE 30 SUCTION
32 REDUCED PRESSURE SCREEN
27 OIL
33 CONVERTER PRESSURE COOLER
34 RETURN OIL
TO
T192490 LUBE
Transmission Control Circuit—First Forward, Park Brake Off, Bypass Closed
BT40170,00000B3 –19–12DEC03–1/2

092005
PN=602
9020-15-2 - A 9020-15-2 - B
Transmi
T192490 –19–1
1 KR 2 K4 HIGH 3 K1 4 K3
REVERSE RANGE 1ST SPEED 3RD S
CLUTCH FORWARD CLUTCH CLUTC
CLUTCH
7 8 9 10
TRANSMISSION
TEMPERATURE
SENSOR 18 T
17 SYSTEM
16 TRANSMISSION 21 TORQUE PRESSURE
CONTROL VAVLE CONVERTER REGULATIN
INLET VALVE
PRESSURE
24 TORQUE TEST PORT
CONVERTER
OUTLET 25
PRESSURE
TORQUE 23 TORQUE
TEST PORT
CONVERTER CONVERTER
BACK PRESSURE 22 TORQUE
VALVE CONVERTE
RELIEF
VALVE
26 THERMAL
RELIEF
BYPASS
31 MAIN PRESSURE VALVE
32 REDUCED PRESSURE
27 OIL
33 CONVERTER PRESSURE COOLER
34 RETURN OIL
TO
T192490 LUBE
TM2075 (03
9020-15-2 - A
smission Control Circuit—First Forward

–19–19DEC03
3 5 KV LOW 6 K2 13 PARK
RD SPEED RANGE 2ND SPEED BRAKE
LUTCH FORWARD CLUTCH
CLUTCH
14 PARK
BRAKE
11 12
SWITCH
15
PARK
M 19 SYSTEM PRESSURE BRAKE
URE TEST PORT SOLENOID
ATING
20 FILTER
RELIEF
VALVE
E
RTER
29 TRANSMISSION
PUMP
28 SYSTEM
PRESSURE
RELIEF
VALVE 30 SUCTION
SCREEN
Transmission Control Circuit—First Forward, Park Brake Off, Bypass Closed

BT40170,00000B3 –19–12DEC03–1/2
5 (03MAR05) 9020-15-2 644J and 724J Loader

092005
PN=602
9020-15-2 - B
1—Reverse Clutch (KR) 10—Proportional Solenoid 18—Transmission 26—Thermal Relief Bypass

2—High Range Forward Clutch Valve (Y4) Temperature Sensor Valve
(K4) 11—Proportional Solenoid 19—System Pressure Test 27—Oil Cooler
3—First Speed Clutch (K1) Valve (Y5) Port 28—System Pressure Relief
4—Third Speed Clutch (K3) 12—Proportional Solenoid 20—Filter Relief Valve Valve
5—Low Range Forward Clutch Valve (Y6) 21—Torque Converter Inlet 29—Transmission Pump
(KV) 13—Park Brake Pressure Test Port 30—Suction Screen
6—Second Speed Clutch (K2) 14—Park Brake Switch 22—Torque Converter Relieve 31—High Pressure Oil
7—Proportional Solenoid 15—Park Brake Solenoid Valve 32—Reduced Pressure
Valve (Y2) 16—Transmission Control 23—Torque Converter 33—Converter Pressure
8—Proportional Solenoid Valve 24—Torque Converter Outlet 34—Return Oil
Valve (Y1) 17—System Pressure Pressure Test Port
9—Proportional Solenoid Regulating Valve 25—Torque Converter Back
Valve (Y3) Pressure Valve
BT40170,00000B3 –19–12DEC03–2/2
9020
15
3

092005
PN=603
Power Train Component Location

T151532 –19–22FEB02
BT40170,00000B2 –19–12DEC03–1/2

092005
PN=604
9020-15-4 - A 9020-15-4 - B
Power T
T151532 –19–2
TM2075 (03
9020-15-4 - A
er Train Component Location

–19–22FEB02
BT40170,00000B2 –19–12DEC03–1/2
5 (03MAR05) 9020-15-4 644J and 724J Loader

092005
PN=604
9020-15-4 - B
1—Park Brake 6—Transmission Oil Thermal 9—Brake Inspection Port 12—Transmission Filter
2—Transmission Bypass Valve 10—Axle Oil Circulation 13—Park Brake Solenoid
3—Torque Converter 7—Transmission Oil Cooler Motor/Pumps 14—Axle Dipstick—Front
4—To Hydraulic Pump 8—Axle Dipstick—Rear 11—Transmission Control
5—To Hydraulic Reservoir Valve
BT40170,00000B2 –19–12DEC03–2/2
9020
15
5

092005
PN=605
Diagnose Transmission System Malfunctions

Transmission Clutch Slippage Low oil level See Transmission, Hydraulic

System, Park Brake, and Differential
Oil. (Operator’s Manual.)
Wrong oil grade See Transmission, Hydraulic

Restricted transmission pump Remove and clean screen.

suction screen
Plugged orifice in control valve Inspect and clean orifice. See

(Group 0360.)
Leak in transmission control valve or Remove valve and inspect gaskets.

gasket See Transmission Control Valve
Repair. (Group 0360.)
Low transmission pump flow due to See Transmission Pump Flow Test.
worn pump (Group 9020-25.)
Weak or broken pressure regulating See Transmission System Pressure

9020
15 valve spring Test. (Group 9020-25.)
6
Control valve See Transmission Clutch Pressure
Stuck solenoid valve See Transmission Control Valve

Solenoid Check (S.N. —590067).
(Group 9015A-15.) Or see
Check (S.N. 590068— ). (Group
9015B-15.)
Remove and inspect solenoid valve.

Damaged clutch sealing ring Remove cover and inspect rings.

See Remove Clutches, Input And
Output Shafts. (Group 0360.)
Worn clutch pack Check shift times in manual mode.
Continued on next page TX,9020,ME444 –19–12DEC03–1/15

092005
PN=606
Clutch pack leakage See Transmission System Leakage

TX,9020,ME444 –19–12DEC03–2/15
Machine Will Not Move Diagnostic Trouble Code problem Check Diagnostic Trouble Codes to
define problem. See Diagnostic
Trouble Codes (DTC) (S.N. —
590067) or See Diagnostic Trouble
Codes (DTC) (S.N. 590068—).
(Group 9005-10.)
Applied park brake Check park brake fuse. See

Functional Schematic And
Component Location Legend
(S.N. —590067). (Group 9015A-15.)
Or see Fuse and Relay
(Group 9015B-10.)
See Continuity Check For Sensors

With Two Wires (S.N. —590067).
(Group 9015A-20.) Or see Sensor 9020
Circuitry Check (S.N. 590068— ). 15
(Group 9015B-20.) 7
Low oil level Check transmission oil level.
Clutch cut-off activated Check that brake pedal is fully

released.
No power to Transmission Control Check Transmission Controller

Unit Switched 5 A fuse. See Fuse
Specifications (S.N. —590067). (Go
to 9015A-10.) Or see Fuse and
Relay Specifications (S.N. 590068—
). (Group 9015B-10.) See Load
Center Harness (W3) Component
Location (S.N. —590067). (Group
9015A-10.) Or see Load Center
Harness (W3) Component Location
(S.N. 590068— ). (Group 9015B-10.)

092005
PN=607
Check Monitor and Transmission

Controller unswitched fuse. See
Fuse Specifications (S.N. —590067).
(Group 9015A-10.) Or see Fuse and
). (Group 9015B-10.) See Load
Center Harness (W3) Component
Location (S.N. —590067). (Group
9015A-10.) Or see Load Center
(S.N. 590068— ). (Group 9015B-10.)
Hydraulic failure of park brake Park brake light on.
See Driveline Bearing—Park Brake

Pressure Test. (Group 9020-25.)
If park brake light is off, inspect park

brake. See Remove And Install Park
Brake. (Group 1111.)
Malfunctioning park brake solenoid Remove and inspect park brake

valve solenoid valve. See Remove And
Install Park Brake Release Solenoid
Valve. (Group 1160.) Check for
9020
15 power to solenoid valve.
8
Failed shift switch Check that basic display window
shows correct gear when shift switch
is moved. See Monitor Display
Unit—Normal Display (S.N. —
590067). (Group 9015A-15.) Or see
CAN Monitor Unit (CMU) Circuit
). (Group 9015B-15.)
Excessive leakage in transmission See Transmission System Leakage

Low or no transmission pressure See Transmission System Pressure


092005
PN=608
Failed torque converter Check torque converter output speed

in neutral, should equal engine rpm.
Use diagnostic mode d 054. See
Menu (S.N. —590067), Transmission
Sensors (d 05). (Group 9015A-15.)
Or see Monitor Display Unit—Main
Menu—Diagnostics—Transmission.
(Operator’s Manual.)
Broken shafts or gears Drain transmission to determine if

large pieces of metal contamination
are present.
Broken drive shafts Inspect drive shafts and universal

joints for external damage. See
Remove And Install Universal Joint
And Universal Drive Shaft. (Group
0225.)
Broken ring or pinion gear If drive shafts rotate with

transmission in gear but machine
does not move, a differential failure
is indicated. See Remove and Install
Universal Joint and Universal Drive
9020
Shaft. (Group 0225.) 15
9

092005
PN=609
Machine Does Not Engage In Clutch cut-off activated Check that brake pedal is fully
Low Gear released.
Shift switch problem See Diagnostic Trouble Codes

(DTC) (S.N. —590067). (Group
9015A-20.) Or see Complete
Machine Operational Checkout.
(Group 9005-10.)
Malfunctioning transmission control See Transmission Control Valve

solenoid valve Solenoid Check (S.N. —590067).
(Group 9015A-15.) Or see
9015B-15.)
Stuck spool in transmission control Remove and inspect transmission

valve control valve spools. See
(Group 0360.)
Plugged orifice in control valve Remove control valve to inspect.

Replace if necessary. See
(Group 0360.)
9020
15
10 Failed sealing ring Remove first gear sealing ring cover
an inspect. See Remove Clutches,
Input And Output Shafts. (Group
0350.)

092005
PN=610
Machine Will Not Shift Correctly Transmission shifts fast in fourth Wrong Transmission Control Unit for
gear automatic machine model number. Install
correct controller.
Transmission will not shift out of Wrong Transmission Control Unit for
second in automatic mode machine model number. Install
correct controller.
Speed sensor disconnected or failed See Monitor Display Unit—

Diagnostics Menu (S.N. —590067),
Transmission Sensors (d 05). (Group
9015A-15.) Or see Monitor Display
Unit—Main Menu—Diagnostics—
Transmission. (Operator’s Manual.)
Transmission Control Unit failure See Check Controller (S.N. —

590067). (Group 9015A-20.) Or see
Transmission Control Unit (TCU)
Circuit Theory of Operation (S.N.
590068— ). (Group 9015B-15.)

9020
15
11

092005
PN=611
Transmission System Pressure Is Low oil level Check transmission oil level and refill
Low In Neutral if necessary.
Transmission filter clogged Replace filter.
Park brake light on Low park brake pressure, check

transmission system pressure. See
Transmission System Pressure Test.
(Group 9020-25.)
Plugged suction screen Transmission pump may be noisy if

transmission suction screen is
clogged. Disassemble transmission
to remove and clean suction screen.
Stuck transmission pressure Remove transmission pressure

regulating valve or broken spring regulating valve. Inspect for damage.
See Transmission Pump Remove
and Install, remove and install
converter minimum pressure
regulator valve. (Group 0360.)
Failed control valve gasket Inspect transmission control valve for

external leakage. Remove control
valve. Inspect or replace gasket. See
9020
15 Transmission Control Valve Repair.
12 (Group 0360.)
Seal blown on solenoid valve Inspect solenoid valve. See

(Group 0360.)
Failed transmission pump See Transmission Pump Flow Test.

(Group 9020-20.)

092005
PN=612
Transmission System Pressure Is Failed transmission control valve Inspect transmission control valve for
Low (One Or Two Gears) gasket external leakage. Remove control
valve. Inspect or replace gasket. See
(Group 0360.)
Leakage in clutch piston or seal ring Air check to confirm leak.

Disassemble and repair. See
Disassemble Clutch Pack KV And
KR. (Group 0350.)
Solenoid valve malfunction Check for a transmission service

code on monitor, then check
solenoids using Monitor diagnostics.
See Monitor Display Unit—
Diagnostic Trouble Code (DTC) (d
01). (Group 9015A-15.) Or see
9015B-20.)
9020
15
13

092005
PN=613
Transmission Shifts Too Slow Low oil level (aeration of oil) Add oil.
Low transmission pressure If park brake light is on, do

transmission system pressure test.
See Transmission System Pressure
Restricted transmission pump Disassemble transmission to remove

suction screen and clean suction screen. See
(Group 0360.)
Low transmission pump flow See Transmission Pump Flow Test.

(Group 9020-25.)
Excessive transmission internal See Transmission System Leakage

leakage Test. (Group 9020-25.)
Transmission Control Unit is Program for correct machine model

programmed incorrectly and accessories with monitor. See
Monitor Display Unit—Accessing
Menus (S.N. —590067). (Group
9015A-15.) Or see CAN Monitor Unit
(CMU) Circuit Theory of Operation
(S.N. 590068— ). (Group 9015B-15.)
9020
15
14 Plugged orifice in control valve Inspect and clean orifice. See
(Group 0360.)
Restricted oil passages between Remove control valve and inspect oil
control valve and transmission. passages. See Remove Hydraulic
Control Valve. (Group 0360.)

092005
PN=614
Transmission Shifts Too Fast Failed speed sensor See Monitor Display Unit—
Transmission Sensors (d 05). (Group
9015A-15.) Or see Monitor Display
Unit—Main Menu—Diagnostics—
System pressure too high See Transmission System Pressure

Broken piston return spring Disassemble and inspect clutch. See

Remove Clutches, Input and Output
Shafts. (Group 0350.)
Transmission Control Unit See Check Controller (S.N. —

590067). (Group 9015A-20.) Or see
Transmission Control Unit (TCU)
Circuit Theory of Operation (S.N.
590068— ). (Group 9015B-15.)
Machine "Creeps" In Neutral Warped disks and plates in two pack Check transmission. See Remove
of transmission Transmission Pump. (Group 0360.)
Control valve leakage See Transmission System Leakage

9020
15
Plugged screen on solenoid valve Remove solenoid valve and clean. 15

092005
PN=615
Transmission Hydraulic System High oil level Transmission overfilled or hydraulic

Overheats pump seal leaking.
Low oil level See Transmission, Hydraulic

Wrong oil grade See Transmission, Hydraulic

Park brake dragging Check for heat in park brake area.
Pinched, restricted or leaking lube Check cooler lines.

lines
Malfunction in temperature gauge or Install temperature sensor to verify

sender temperature.
Restricted air flow through oil cooler Check for debris. Straighten fins.
or radiator
Failed oil cooler bypass valve (in Disassemble and inspect. See
thermal bypass valve) Hydraulic System Component
Location. (Group 9025-15.)
9020
15
16 Failed thermal bypass valve Remove thermal bypass valve and
check to see if machine still
overheats. See Transmission Oil
Cooler Thermal Bypass Valve Test.
(Group 9020-25.)
Internally restricted oil cooler See Transmission Oil Cooler

Restriction Test. (Group 9020-25.)
Missing turbulators in oil cooler Replace oil cooler. See Remove And
Install Radiator, Oil, And Air Cooler.
(Group 5010.)
Leakage in transmission hydraulic See Transmission System Pressure

system Test and see Converter-Out Flow
Malfunction in converter relief valve See Converter-Out Pressure Test.

or circuit (Group 9020-25.)

092005
PN=616
Low transmission pump output See Transmission Pump Flow Test.

(Group 9020-25.)
Excessive Transmission Noise Too low engine slow idle Check engine slow idle speed. See
(under load or no load) Throttle Position Sensor Adjustment
(S.N. —590067). (Group 9015A-20.)
Worn parts or damaged in Disassemble transmission to inspect

transmission suction screen for metal particles.
Repair as necessary. See
Transmission Remove And Install.
(Group 0300.)
Damaged drive dampener Inspect drive dampener.
Converter bearings failed Replace converter. See Torque

Converter Remove and Install.
(Group 0350.)
Low or no lube See Converter-Out Pressure Test

and see Lube Pressure Test. (Group
9020-25.) See Transmission Pump
Flow Test. (Group 9020-25.)
Driveline or park brake Inspect drive line and park brake.

9020
15
Foaming Oil Incorrect type of oil Change oil. See Transmission, 17
High oil level Transmission overfilled or hydraulic

pump seal leaking.
Low oil level Add oil. See Transmission, Hydraulic

Air leak on suction side of pump Check oil pickup tube on inside of
transmission.
Oil Ejected From Dipstick Plugged breather Inspect breather on top of

transmission. Replace.

092005
PN=617
Machine Vibrates Aerated oil Add oil. See Transmission, Hydraulic

Low engine speed Check engine speed. See Throttle

Position Sensor Adjustment (S.N. —
590067). (Group 9015A-20.)
Failed universal joints on Check universal joints. See Remove

transmission drive shaft or And Install Universal Joint And
differential drive shafts Universal Drive Shaft. (Group 0225.)
Damaged drive dampener Inspect drive dampener.
Machine Lacks Power And Engine fast idle speed set too low Adjust engine fast idle. See Throttle
Acceleration Position Sensor Adjustment (S.N. —
590067). (Group 9015A-20.)
Incorrect transmission oil Drain transmission oil and refill. See

Change Transmission Oil.
Aerated oil Check oil quality and add oil.
Warped transmission clutch Check transmission drag.

9020
15
18 Torn transmission control valve Inspect gasket.
gasket
Failed torque converter See Torque Converter Stall Speed

Low engine power Perform Engine Power Test Using

Turbocharger Boost Pressure.
(Group 9010-25.)
Converter relief valve stuck open Inspect and repair. See Remove,
Disassemble, And Install Converter
Relief Valve. (Group 0360.)

092005
PN=618
Torque Converter Stall rpm Too Aerated oil Put clear hose on thermal bypass
High outlet port. Run machine to check for
bubbles in oil.
Stuck open converter relief valve See Converter-Out Pressure Test.

(Group 9020-25)
Leakage in torque converter seal See Converter-Out Pressure Test.

(Group 9020-25.)
Torque converter not transferring Replace torque converter. See

power (bent fins, broken stator) Torque Converter Remove and
Install. (Group 0300.)
Torque Converter Stall rpm Too Low engine power Perform Engine Power Test Using
Low Turbocharger Boost Pressure.
(Group 9010-25.)
Mechanical malfunction Remove and inspect torque

converter. See Remove Torque
Converter. (Group 0350.)
Engine fast idle speed set too low Adjust engine fast idle. See Throttle
Position Sensor Adjustment (S.N. —
590067). (Group 9015A-20.)
9020
15
19
TX,9020,ME444 –19–12DEC03–15/15

092005
PN=619
Diagnose Differential And Axle Malfunctions

No differential Lock Operation Malfunction in electrical circuit With engine stopped and key switch
on, activate differential lock and
listen for a click from solenoid valve.
See Complete Machine Operational

Checkout. (Group 9005-10.)
Stuck differential lock solenoid valve With engine stopped and key switch
Remove and inspect valve. See
Remove And Install Differential Lock
Solenoid Valve. (Group 3160.)
Malfunction in pressure reducing See Differential Lock Pressure Test.

valve or setting low (Group 9025-25)
Excessive leakage in differential lock See Differential Lock Pressure Test.

piston seals (Group 9025-25)
Stuck differential lock piston Disassemble, inspect, repair. See

Disassemble and Inspect
Limited-Slip Differential. (Group
9020
15 0250.)
20
Excessive wear on differential lock Disassemble, inspect, repair. See
disks and plates Disassemble and Inspect
0250.)

092005
PN=620
Differential Lock Slips Or Axle oil broken down Change axle oil. See Change Front
Chatters When Engaged and Rear Differential Oil. (Operator’s
Manual.)
Malfunction or setting low on See Pressure Reducing Valve

pressure reducing valve Pressure Test. (Group 9025-25.)
Remove and inspect regulating
valve.
Excessive leakage differential lock See Differential Lock Pressure Test.

piston seals (Group 9025-25.)
Failed seals on differential lock Remove and inspect seals. See

solenoid valve or regulating valve Remove And Install Differential Lock
Stuck differential lock piston Disassemble, inspect and repair.

See Differential Lock Pressure Test.
(Group 9025-25.)
Excessive wear of differential lock Disassemble, inspect, and repair.

disks and plates See Differential Lock Pressure Test.
(Group 9025-25.)
Warped differential lock disks and Disassemble, inspect, and repair.

9020
plates See Differential Lock Pressure Test. 15
(Group 9025-25.) 21
Stuck differential lock piston Disassemble, inspect, and repair.

See Differential Lock Pressure Test.
(Group 9025-25.)

092005
PN=621
Differential Lock Will Not Release Stuck foot switch Inspect.
Malfunction in electrical circuit With engine stopped and key switch

See Brake System, Clutch Cut-off,
And Differential Lock Checks.
(Group 9005-10.)
Stuck differential lock solenoid valve With engine stopped and key switch
Stuck differential lock piston Disassemble, inspect, repair. See

Disassemble and Inspect
0250.)
Warped differential lock disks and Disassemble, inspect, repair. See

plates Disassemble and Inspect
0250.)
9020
15
22 Differential Overfilled With Oil Differential lock piston leaking Replace differential lock piston seal.
See Disassemble and Inspect
0250.)
Leak in brake piston seals Remove differential check plugs and

check leakage from check plug with
brakes applied.
Differential Low On Oil External leakage Inspect axle and differential for
leaks.

092005
PN=622
Excessive Differential And/Or Low oil level in differential Check oil. Remove drain plug and
Axle Noise inspect for metal particles in
differential case. Disassemble and
determine cause. See Check Front
and Rear Differential Oil Level.
Dragging brakes See Brake System, Clutch Cut-off,

And Differential Lock Checks.
(Group 9005-10.)
Engaged differential lock Release lock.
If circuit remains pressurized, check

if foot switch is sticking. Remove and
inspect.
Check solenoid valve for sticking.

Failed pinion bearing Remove and inspect pinion. Check

to ensure pinion housing was
indexed. See Disassemble, Inspect,
9020
and Assemble Hydraulic Differential 15
Lock Differential. (CTM150.) 23
Incorrect gear mesh pattern between Remove pinion gear housing and
ring and pinion gear inspect ring and pinion gear. See
Disassemble, Inspect, and Assemble
Hydraulic Differential Lock
Differential. (CTM150.)
Failed differential pinion gears and/or Remove differential housing drain

cross shafts plug and inspect for metal particles.
Disassemble and inspect. See
Disassemble, Inspect, and Assemble
Hydraulic Differential Lock
Differential. (CTM150.)
Failed axle bearing Replace Axle Bearing. See

Disassemble Final Drive/Axle
Housing Assembly. (CTM150.)

092005
PN=623
Mechanical failure in axle planetary Repair differential. See Remove And

Install Front Axle And Differential.
(Group 0200.)
Defective axle circulation motor dual See Axle Circulation Motor and Dual
pump. Pump Flow Test. (Group 9020-25.)
Oil Seeping From Outer Axle Dirt in face seal Inspect or replace face seals. See
Seal Disassemble Final Drive/Axle
Face seal out of place. Replace face seal. See Disassemble

Final Drive/Axle Housing Assembly.
(CTM150.)
Excessive end play in axle Inspect Axle Bearing and Adjust or

replace as needed. See
Worn outer bearing and/or cup Inspect Axle Bearing and Adjust or
replace as needed. See
9020
15 Overfilled differential Check differential lock oil return
24 system for excessive internal
restriction. See Remove And Install
Differential Lock Solenoid Valve.
(Group 3160.)
High pressure in axle Check Axle Breather. See Axle

Breather Test. (Group 9020-25.)

092005
PN=624
Axle Overheats Low differential oil Add oil. See Check Front and Rear
Differential Oil Level. (Operator’s
Manual.)
Overfilled differential See Differential Overfills with Oil in

this group.
Brake drag Perform External Service Brake

Inspection. (Group 9020-20.)
Axle circulation motor dual pump See Axle Circulation Dual Pump
Flow and Temperature Tests. (Group
9020-25.)
Axle circulation motor dual pump Inspect axle circulation filter screen
screens plugged located in differential housing below
input yoke. See Clean Axle
Differential Circulation Screen.
TX,9020,ME445 –19–12DEC03–6/6
9020
15
25

092005
PN=625
Diagnose Service Brake Malfunctions

Poor or No Brakes Axle overheated See Axle Circulation Dual Pump

Flow and Temperature Tests. (Group
9020-25.)
Brake disks worn or warped See External Service Brake

Inspection. (Group 9020-20.)
Brake pressure low See Brake Valve Pressure Test.

(Group 9025-25.)
Leakage in brake piston seals Check differential oil level. If over

filled, brake system or differential
lock is leaking.
Brake valve leaking internally See Brake Valve Leakage Test.

(Group 9025-25.)
Brake shuttle valve stuck Remove and disassemble to repair.

See Service Brake Valve. (Group
9025-25.)
Aggressive Brakes Clutch cut-off mode set to Steep Turn clutch cut-off switch off.
Slope
9020
15
26 Brake Valve Malfunction Disassemble and inspect. See Brake
Valve Remove And Install. (Group
1060.)
Brakes Drag Brake pedal not returning Inspect floor mat and pedal.
Brake valve piston not returning to Disassemble and inspect. See Brake
neutral position. Valve Remove And Install. (Group
1060.)
Brake piston not returning. Disassemble axle and inspect brake

pistons. See Front Axle And
Differential Remove and Install.
(Group 0200.)

092005
PN=626
Brakes Chatter Brake disk friction material worn Inspect brake disks. See External
Service Brake Inspection. (Group
9020-20.)
Oil broken down Change oil. See Change Front and

Rear Differential Oil. (Operator’s
Manual.)
Wrong oil in hydraulic system Drain hydraulic reservoir and

differentials. Refill with correct oil.
See Change Front and Rear
See Excessive Differential or Axle

Noise in this group.
Hissing Noise When Brake Pedal Brake valve or brake piston leakage See Brake Valve Leakage Test.
is Pushed (Group 9025-25.)
Brake Pressure Indicator Light Brake accumulator pressure too low See Brake Accumulator Precharge
Will Not Go Out Or Stays On Test. (Group 9025-25.)
Excessively Long After Start-up
Brake Pressure Switch Replace switch. See Remove And

Install Park Brake Pressure Switch.
9020
(Group 1160.) 15
27
Low hydraulic pump low standby See Hydraulic Pump Margin And
pressure too low Low Standby Pressure Adjustment
TX,9020,ME446 –19–12DEC03–2/2

092005
PN=627
Diagnose Drive Line Malfunctions

Excessive Drive Line Vibration Yokes not in line on drive shafts Inspect. Align drive shaft yokes. See
Or Noise Remove And Install Universal Joint
And Universal Drive Shaft. (Group
0225.)
Worn park brake bearings Inspect, repair. See Disassemble

And Assemble Park Brake. (Group
1111.)
Lack of lube in park brake Inspect park brake oil level and
adjust as required. See Check Park
Brake Oil Level. (Operator’s
Manual.)
Bent drive shaft Inspect all drive shafts. Replace.

See Universal Joint And Universal
Drive Shaft Repair. (Group 0225.)
Loose yoke retaining nuts (drive Inspect. Replace. See Universal

shafts wobble at high speed) Joint And Universal Drive Shaft
Rear axle oscillating support Inspect. See Disassemble And

9020
15 Assemble Axle Oscillating Supports.
28 (Group 0200.)
Lack of lubrication Lubricate with proper grade of

grease. See Grease. (Operator’s
Manual.)
TX,9020,ME447 –19–12DEC03–1/1

092005
PN=628
Diagnose Park Brake Malfunctions
Brake Will Not Hold Piston seals leaking and oil coming Replace seals. See Disassemble
out of the breather And Assemble Park Brake. (Group
1111.)
Breather plugged Inspect and clean breather.
Malfunctioning park brake solenoid Inspect and replace
Worn brake disk and/or plates Disassemble, inspect, repair. See

Disassemble And Assemble Park
Brake piston hangs up in bore Remove and inspect. Repair. See

Broken springs in park brake Inspect and repair park brake. See

9020
15
29

092005
PN=629
Brake Overheats Overfilled with oil. Adjust oil level.See Check Park
Brake Oil Level. (Operator’s
Manual.)
Solenoid not functioning properly See Driveline Bearing Park Brake

Breather plugged Inspect and clean breather.
Low transmission pressure Test Park Brake pressure. See

Driveline Bearing Park Brake
Brake disk or plates warped Inspect and repair. See Disassemble

And Assemble Park Brake. (Group
1111.)
Brake drags Park Brake Pressure Test. (Group

9020-25.)
Disassemble, inspect brake. Repair

if necessary. See Disassemble And
Assemble Park Brake. (Group 1111.)
Bearing failure in park brake Disassemble, inspect brake. Repair

9020
15 if necessary. See Disassemble And
30 Assemble Park Brake. (Group 1111.)
Park Brake Indicator In Monitor Low oil level Add oil.

Comes On When Shifting From
Fwd to Rev (All Other Gears OK)
Cold oil Warm oil to specification. See

Transmission Oil Warm-Up
Solenoid not functioning Inspect or repair. See Park Brake

Release Solenoid Valve Remove
And Install. (Group 1160.)

092005
PN=630
Park Brake Light Comes On For Cold oil Warm oil to specification. See
Each Shift Transmission Oil Warm-Up
Low transmission pressure See Transmission System Pressure

Leak in transmission pressure circuit See Converter-Out Pressure Test.

(Group 9020-25.)
Failed transmission pump See Transmission Pump Flow Test.

(Group 9020-25.)
Malfunctioning park brake solenoid See Park Brake Pressure Test.

(Group 9020-25.) Or replace park
brake solenoid.
Park Brake Indicator In Monitor Faulty wiring or switch Inspect for loose or broken wires
Does Not Come On When Brake between brake indicator switch and
Applied indicator on dash.
Do Continuity Test using Monitor.

See Continuity Check For Sensors
With Two Wires (S.N. —590067).
(Group 9015A-20.) Or see Sensor
9020
Continuity Check (S.N. 590068— ). 15
(Group 9015B-20.) 31
Brake Will Not Apply Malfunctioning wiring, switch, or Check electric circuit. See Park
solenoid Brake Circuit Theory Of Operation
(S.N. —590067). (Group 9015A-15.)
Or see Transmission Control Unit
(TCU) Circuit Theory of Operation
(S.N. 590068— ). (Group 9015B-15.)
Restriction between transmission Remove hose and inspect. Replace.

port and park brake valve
TX,9020,ME448 –19–12DEC03–3/3

092005
PN=631
9020
15
32

092005
PN=632
Group 20
Adjustments
External Service Brake Inspection
SPECIFICATIONS
Used Service Brake Disk 2.29 mm
Thickness Distance 0.090 in.
New Service Brake Disk 2.90 mm
Thickness Distance 0.114 in.

Feeler Gauge
CAUTION: Prevent possible injury from hot

spraying oil. Slowly loosen plug to relieve any
pressure.
IMPORTANT: Perform first inspection at 5000 hours

followed by 1000 hour inspection
intervals after the first inspection.
If the service brakes are subjected to

severe duty, inspect more frequently.
1. Remove plug from brake inspection port.
2. Start engine and operate for one minute.
3. Stop and apply the brakes. Block pedal or have 9020

20
someone hold brakes on.
1

092005
PN=633
Adjustments
4. Using a feeler gauge at (A) measure the thickness of

disks at dimension (B). Check dimension of two
different disks.
A—Feeler Gauge
–UN–02NOV98
B—Disk Thickness
T105193B
–UN–25FEB97
T105767B
CED,TX13067,43 –19–29SEP03–2/3
9020
20
2
Specification
Used Service Brake Disk
Thickness—Distance .................................................................... 2.29 mm
0.090 in.
Specification
New Service Brake Disk
Thickness—Distance .................................................................... 2.90 mm
0.114 in.
5. If any of the disks thickness at dimension (B) is less

than the minimum specification, the brake packs must
be replaced.
A—Disks
B—Disk Thickness
C—Plates
–19–12FEB97
T106873
CED,TX13067,43 –19–29SEP03–3/3

092005
PN=634
Adjustments
Transmission Control Unit (TCU)—Electronic X53

Clutch Adjustment (S.N. —590067) TCU DIAGNOSTIC AND
PROGRAMMING CONNECTOR
SPECIFICATIONS
Engine Speed 900 ± 25 rpm
Transmission Oil Temperature 80 ± 6°C (176 ± 10°F)
ESSENTIAL TOOLS
JT07356-3 Harness Adaptera
JT07356-1 Displaya
–19–06JUN00
JT07356-2 Trigger Controla
a
Contained inside JT07356 TCU Electronic Clutch Adjustment Kit
NOTE: This adjustment is required after a tractor has
T131294
transmission rebuilt, replaced or Transmission T131294
Control Unit (TCU) is replaced. It is also Diagnostic & Programming Connector
recommended to perform this adjustment after all
transmission oil change intervals including the
initial 100 hour interval on new tractor or
transmission. The adjustment will optimize the
clutch pack shift operation by electronically
adjusting the transmission controller unit for the
exact transmission used in the tractor. Adjustment
requires JT07356 TCU Electronic Clutch
Adjustment Kit . This kit contains three tools:
JT07356-1 Display, JT07356 -2 Trigger Control, 9020
and JT07356-3 Harness Adapter. 20
3
1. Open load center panel on right outside of cab and
locate TCU diagnostic and programming 6 pin
connector (X53). Remove dust cover from connector.
–19–16SEP99
T123299
TCU Electronic Clutch Adjustment Kit Connections
Continued on next page CED,TX04577,848 –19–11DEC03–1/4

092005
PN=635
Adjustments
NOTE: Transmission oil temperature must be warmed to

specification when doing this adjustment. If oil
temperature drops below specification while
performing adjustment you must disconnect from
harness from connector to allow transmission to
be warmed up again. Then reconnect and
continue doing adjustment.
2. Heat transmission oil to test specifications. Use the

monitor or SERVICE ADVISOR™ system to read
engine rpm and transmission oil temperature. See
Monitor Display Unit—Diagnostics Menu (S.N. —
590067), Transmission Sensors (d 05) and Hydraulic
Sensors (d 06). (Group 9015A-15.)
Or access Transmission Oil Tests SERVICE ADVISOR

system template. See Service ADVISOR System
Computer Connection for information on connecting to
J-Series loaders (S.N. —590067).
Specification
Engine—Speed .................................................................... 900 ± 25 rpm
Transmission Oil—Temperature............................. 80 ± 6°C (176 ± 10°F)
3. Connect JT07356-3 harness adapter to 6 way

connector coming from TCU load center harness.
9020 4. Connect JT07356-1 display with 3 pin connector to

20 harness adapter.
4
5. Connect JT07356-2 trigger control with 6 pin connector

(only 4 used) to harness adapter.
NOTE: Engine speed must be at proper specified speed

when doing electronic clutch adjustment.
6. Run engine at slow idle. Park Brake “ON” and “Auto”

transmission switch in the off position.
7. Press and hold start button on trigger control until

display module indicates to start activation process.
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page CED,TX04577,848 –19–11DEC03–2/4

092005
PN=636
Adjustments
8.Display
Symbol Meaning Remarks
PL Trigger control is plugged into diagnostic plug on
tractor.
ST Button at the trigger control is pressed.
K1,K2,K3,K4,KV,KR Clutch number being adjusted
One bar and clutch number (K1...etc) Wait for start, initialization of clutch being adjusted
Two bars and clutch number (K1...etc) Compensating pressure determined by clutch
Three bars and clutch number (K1...etc) Fast fill time determined by clutch
OK Trigger Control has been successfully completed
Stop Trigger Control canceled (activation stopped). Transmission stays in neutral, you have
to restart the TCU by turning key Off &
On.
Stop and Clutch number (K1... etc.) Trigger Control stopped. Clutch number shown cannot Transmission stays in neutral, you have
be calibrated to restart the TCU by turning key Off &
On.
Spanner and Clutch number (K1... etc.) Clutch number shown could not be calibrated. Trigger Transmission stays in neutral, you have
controller is finished. to restart the TCU by turning key Off &
On.
Diamond shape facing up with a letter Engine speed to high Lower engine speed
"E"
Diamond shape facing down with a letter Engine speed to low Raise engine speed
"E"
Diamond shape facing up with a letter Temperature to low Warm up oil
"T"
Diamond shape facing down with a letter Temperature to high Cool down oil
"T" 9020
20
FT Transmission temperature not in defined range during Transmission stays in neutral, you have
5
calibration to restart the TCU by turning key Off &
On.
FB Operating mode not NORMAL or transmission sensor Transmission stays in neutral, you have
defective or storing of calibrated values to EEPROM to restart the TCU by turning key Off &
has failed On.
FO Output speed not zero Transmission stays in neutral, you have
On.
FN Shift lever not in neutral position Transmission stays in neutral, you have
On.
FP Park Brake not applied Transmission stays in neutral, you have
On.
Stop Trigger Controller was used incorrectly or is defective Transmission stays in neutral, you have
On.
Continued on next page CED,TX04577,848 –19–11DEC03–3/4

092005
PN=637
Adjustments
The display will read which clutch the trigger control is

currently calibrating. Note: If the transmission falls below
70° C or climbs above 90° C, the display will read “T”
and indicate that the temperature is too low or too high.
Simply warm the transmission up to above 70° C or cool
below 90° C and the trigger control will continue from
where it left off.
If engine speed is raised above 1000 rpm, the display

will read E and indicate that the engine speed must be
lower. Again, the trigger control will pick up from where it
left off once engine speed is below 1000 rpm. When the
trigger control has been fully activated the display will
read OK. Procedure is now completed.
9. Remove harness adapter and connections from load

center harness. Install dust cover on 6 pin connector in
load center harness.
CED,TX04577,848 –19–11DEC03–4/4
9020
20
6

092005
PN=638
Adjustments
Transmission Control Unit (TCU)—Electronic

Clutch Calibration (S.N. 590068— )
NOTE: This adjustment is required after a machine has

transmission rebuilt, replaced, or TCU is replaced.
It is also recommended to perform this adjustment
after all transmission oil change intervals including
the initial service interval on new machine or
transmission. The adjustment will optimize the
clutch pack shift operation by electronically
adjusting the TCU for the exact transmission used
in the machine.
1. The following criteria must be met and maintained for

transmission clutch calibration to start and complete
successfully:
• Engine must be on
• FNR must be in neutral
• Park brake must be ON
• Engine RPM must be lower than 1100 rpm
• Transmission oil temperature must be between 70—
90°C (158—194°F)
2. Perform Transmission Oil Warm-Up Procedure. (Group

9020-25.)
9020
3. Begin transmission clutch calibration by accessing 20
Trans Clutch Cal under Machine Config in the CAN 7
Monitor Unit (CMU). See CAN Monitor Unit (CMU)
Circuit Theory of Operation (S.N. 590068— ). (Group
9015B-15.)
NOTE: While clutch calibration is in process, Trans Clutch

Cal will be displayed at the top of the CMU and
working will be flashing on the bottom of the
CMU.
4. Clutches will be calibrated and displayed on CMU as

follows:
• Adjusting K1
• Adjusting K2
• Adjusting K3
• Adjusting K4
• Adjusting KV
• Adjusting KR
Continued on next page BT40170,0000091 –19–01DEC03–1/2

092005
PN=639
Adjustments
5. If CMU displays the following during calibration, cycle

key switch and start procedure again:
• Shift Not in Neutral

• Park Brake Not ON
• Output Speed Not Zero
If CMU displays the following during calibration, make

required adjustment and continue with procedure:
• Trans Temp too High

• Trans Temp too Low
• Engine RPM too Low
• Engine RPM too High
6. If CMU displays Cancelled or Aborted during

calibration, cycle key switch and start procedure again.
If procedure cancels or aborts again, check for DTCs

on CMU. See Transmission Control Unit (TCU)
Diagnostic Trouble Codes (S.N. 590068— ). (Group
9015B-20.)
If no DTCs exist, diagnose transmission. See Diagnose

Transmission System Malfunctions. (Group 9020-15.)
7. With successful transmission calibration, one of the

9020
20 following will be displayed on the CMU:
8
• Adjustment Complete
Please Restart Engine
• Fault Present
Adjustment Complete
Please Restart Engine
BT40170,0000091 –19–01DEC03–2/2

092005
PN=640
Group 25
Tests
Transmission Oil Warm-Up Procedure
SPECIFICATIONS NOTE: Transmission auto mode and clutch cut-off

Transmission Oil Temperature 74—86°C must be turned off.
166—186°F
2. Fully apply service brakes.
NOTE: SERVICE ADVISOR™ application or vehicle
monitor display can be used to indicate 3. Turn park brake OFF.
transmission oil temperature.
4. Shift to third gear forward.
NOTE: Temperature sensor is located in transmission
control valve. 5. Run engine at fast idle until test specification is met
or for 30 seconds (whichever comes first).
1. Machines (S.N. —590067) display transmission oil
temperature using the monitor. See Monitor Display Specification
Unit—Diagnostics Menu (S.N. —590067), Transmission Oil—Temperature ........................................... 74—86°C
166—186°F
Transmission Sensors (d 05). (Group 9015A-15.) Or
access Transmission Oil Tests SERVICE ADVISOR
6. Reduce speed, shift to neutral and run for 15
system template. See Service ADVISOR System
seconds.
Computer Connection for information on connecting
to J-Series loaders (S.N. —590067).
7. Repeat process until oil is to test specification.
Machines (S.N. 590068— ) display transmission oil
8. Press MENU once to return home screen.
temperature using CAN Monitor Unit (CMU). See
Monitor Display Unit—Main Menu—Diagnostics—
9020
25
1
SERVICE ADVISOR is a trademark of Deere & Company BT40170,0000093 –19–03DEC03–1/1

092005
PN=641
Tests
Driveline Bearing—Park Brake Pressure Test
The purpose of this test is to check that correct pressures

are available to set and release the park brake.
SPECIFICATIONS
Driveline Bearing Park Brake 0 kPa
Pressure, Switch ON 0 bar
0 psi
Driveline Bearing Park Brake 1500—1800 kPa
Pressure, Switch OFF 15—18 bar
218—260 psi
ESSENTIAL TOOLS
38H1030 Tee (-6 M ORFS x -6 F ORFS x -6 M ORFS)
Parker No. 6R6LO-S Tee (-6 M ORFS x -6 F ORFS x -6 M ORFS)

3447 kPa (34.5 bar) (500 psi) Gauge 3447 kPa (34.5 bar) (500 psi)

9020
25
2

092005
PN=642
Tests
–UN–10SEP97
T103068
9020
A—Tee B—Fitting 25
3
1. Connect gauge and fittings (A and B). 9. Compare recorded pressure to specifications.
2. Perform Transmission Oil Warm-Up Procedure in Specification

this group. Driveline Bearing Park Brake—
Pressure, Switch On ................................................................... 0 kPa
0 bar
3. Operate engine at slow idle with transmission in 0 psi
neutral. Driveline Bearing Park Brake—
Pressure, Switch Off ................................................. 1500—1800 kPa
4. Apply service brakes. 15—18 bar
218—260 psi
5. Turn park brake OFF.

• If pressure is too high or low, perform
Transmission System Pressure Test in this group.
6. Record park brake pressure.
• If pressure does not drop to zero when park
brake is ON, remove and inspect park brake
7. Turn park brake ON.
valve. See Park Brake Release Solenoid Valve
Remove And Install. (Group 1160.)
8. Record park brake pressure.
BT40170,0000093 –19–03DEC03–2/2

092005
PN=643
Tests
Driveline Bearing—Park Brake Drag Test
The purpose of this test is to check for excessive brake

drag due to internal damage or wear. This test should be
performed only after Driveline Bearing—Park Brake
Pressure Test is completed.
SPECIFICATIONS
Park Brake Drag Resistance Turn Free with Hand
Drive Shaft Universal Joint Cap 78 N•m
Screw Torque 58 lb-ft
Continued on next page CED,TX17994,359 –19–27JUL00–1/3
9020
25
4

092005
PN=644
Tests
–UN–15JUN98
T115837
9020
A—Drive Shaft (front B—Drive Shaft C—Park Brake 25
axle-to-park brake) (transmission-to-park 5
brake)
4. Remove drive shafts (A and B) from park brake (C)

CAUTION: Prevent possible injury from
only. See Universal Joint And Universal Drive Shaft
unexpected machine movement. Place
Remove and Install. (Group 0200.)
blocks in front and rear of tires to prevent
machine from rolling.
5. Start machine and turn park brake switch OFF.
1. Park machine on level surface. Place blocks in front
6. Turn park brake yoke by hand. Yoke should turn
and rear of tires to prevent machine from rolling.
free with hand.
CAUTION: Prevent possible injury from Specification

unexpected machine movement. Connect Park Brake Drag—Resistance............................ Turn Free with Hand
frame locking bar to both frames before
working in frame pivot area. 7. Turn park brake switch ON and turn machine off.
2. Install fame locking bar. IMPORTANT: Do not reuse drive shaft universal
joint cap screws. Replace cap
3. For machines with column FNR move neutral lock screws to avoid machine damage.
to locked position.
8. Install drive shafts with new capscrews. Tighten to
For machines with joystick FNR, FNR must be must specification.
be in neutral position.

092005
PN=645
Tests
Specification If park brake does not rotate by hand, remove park

Drive Shaft Universal Joint Cap
brake and inspect for worn or damaged parts. See
Screw—Torque ........................................................................ 78 N•m
58 lb-ft Park Brake Remove and Install. (Group 1111.)
CED,TX17994,359 –19–27JUL00–3/3
Transmission Pump Flow Test
The purpose of this test is to determine transmission

pump flow rate and performance.
9020
25
6

092005
PN=646
Tests
1. Remove transmission filter and install JDG596 filter

adapter (1).
NOTE: It may be necessary to install one washer on each

side of spacer when installing filter adapter.
–UN–24OCT03
2. Install flow meter (2) inline back to JDG596 filter
adapter.
IMPORTANT: Before starting engine, check that flow
T195718B
meter loading valve is open. Pump can
be damaged if engine is started with
loading valve closed.
1—Filter Adapter
2—Flow Meter
3. Perform Transmission Oil Warm-Up Procedure in this
group.
4. Operate engine at specified speed with transmission in

neutral.
Specification
Engine—Speed ........................................................................... 1500 rpm
5. Measure pump flow.
Specification
New Pump—Flow (minimum)....................................................... 74 L/min
19 gpm 9020
Used Pump—Flow (minimum) ..................................................... 67 L/min 25
18 gpm 7
Low transmission pump flow can be caused by:
• Low oil level in transmission.

• Cold transmission oil.
• Plugged suction screen.
• Air leak in pump suction tube.
• Worn transmission pump.
BT40170,0000092 –19–03DEC03–2/2

092005
PN=647
Tests
Transmission System Pressure Test
The purpose of this test is to check transmission pump SERVICE EQUIPMENT AND TOOLS
output before it gets routed through the control valve to Gauge 2000 kPa (20 bar) (300 psi)
a clutch pack. This test can also indicate a failed AT202955 Quick Coupler (1/8 x M10 - 1.5 M ORB)
pressure regulating valve or an oil leak before the
control valve.
SPECIFICATIONS
Engine Speed 1500 rpm
Transmission System Pressure 1500—1800 kPa
15—18 bar
218—260 psi
9020
25
8

092005
PN=648
Tests
9020
25
9
–19–19FEB97
T107136
1—System Pressure 5—Clutch Forward High Range 8—Clutch K3 11—Connection from Oil
2—Converter-In Pressure K4 9—Clutch Forward Low Range Cooler
3— Reduced Pressure 6—Reverse Clutch KR (with KV (with quick coupler) 12—Connection to Oil Cooler
4—Transmission Harness quick coupler) 10—Clutch K2 (with quick 13—Converter-Out Pressure
Connector 7—Clutch K1 (with quick coupler)
coupler)
NOTE: Four quick couplers are supplied to points on may be removed and installed into points
the transmission for checking pressure. being tested.
Additional quick couplers may be purchased
through John Deere Parts or existing couplers 1. Connect gauge to test port (1) using quick coupler.

092005
PN=649
Tests
2. Use the monitor or SERVICE ADVISOR™ 4. Operate engine at test specification with
application to read engine rpm and transmission oil transmission in neutral.
temperature.
Specification
Machines (S.N. —590067) use Monitor Display Unit Engine—Speed ..................................................................... 1500 rpm
Diagnostic Mode (d 051) to display transmission
temperature. See Monitor Display Unit—Diagnostics 5. Record pressure with transmission in neutral.
Menu (S.N. —590067), Transmission Sensors (d
05). (Group 9015A-15.) Or access Transmission Oil 6. Compare pressure to specifications.
Tests SERVICE ADVISOR system template. See
Specification
Service ADVISOR System Computer Connection Transmission System—
for information on connecting to J-Series loaders Pressure.................................................................... 1500—1800 kPa
(S.N. —590067). 15—18 bar
218—260 psi
Machines (S.N. 590068— ) see Monitor Display
Unit—Normal Display and see Monitor Display If pressure is low:
Unit—Main Menu—Diagnostics—Transmission.
(Operator’s Manual.) Or use Service ADVISOR • Perform Transmission Pump Flow Test in this
application Transmission Pressure Test template. group. If flow is to specification, inspect pressure
See SERVICE ADVISOR System Computer regulating valve spring in control valve.
Connection for information on connecting to
J-Series loaders (S.N. 590068— ).
3. Perform Transmission Oil Warm-Up Procedure in

this group.
9020
25
10
SERVICE ADVISOR is a trademark of Deere & Company BT40170,0000097 –19–04DEC03–3/3
Transmission Clutch Pressure Test
This test is performed to test modulation circuits which NOTE: Four quick couplers are supplied to points on
electronically control clutch pressure in each clutch. the transmission for checking pressure.
SPECIFICATIONS through John Deere Parts or existing couplers
Engine Speed 1500 rpm may be removed and installed into points
Slow Idle being tested.
Transmission Clutch Pressure 1500—1800 kPa
15—18 bar This test can be performed with one gauge, but the
218—260 psi
test time will be longer. Use six gauges if available.
AT202955 Quick Coupler (1/8 x M10 - 1.5 M ORB)
Gauge 2000 kPa (20 bar) (300 psi)

092005
PN=650
Tests
9020
25
11
–19–19FEB97
T107136
2—Converter-In Pressure K4 9—Clutch Forward Low Range Cooler
3— Reduced Pressure 6—Reverse Clutch KR (with KV (with quick coupler) 12—Connection to Oil Cooler
4—Transmission Harness quick coupler) 10—Clutch K2 (with quick 13—Converter-Out Pressure
Connector 7—Clutch K1 (with quick coupler)
coupler)
1. Connect gauges to transmission clutch points (5—

10).

092005
PN=651
Tests
2. Use the monitor or SERVICE ADVISOR™ leaking. If it is low at both test speeds, a control
application to read engine rpm and transmission oil valve problem could exist.
temperature.
Specification
Machines (S.N. —590067) use Monitor Display Unit Transmission Clutch—Pressure ............................... 1500—1800 kPa
15—18 bar
Diagnostic Mode (d 051) to display transmission 218—260 psi
temperature. See Monitor Display Unit—Diagnostics
Menu (S.N. —590067), Transmission Sensors (d 6. Repeat test for all remaining clutch packs at points
05). (Group 9015A-15.) Or access Transmission Oil (5—10) in neutral. Pressure should be zero in
Tests Service ADVISOR system template. See neutral.
Service ADVISOR System Computer Connection
for information on connecting to J-Series loaders NOTE: Main transmission pressure is used to engage
(S.N. —590067). the clutch packs. If clutch engagement
pressure is below specification, it does not
Machines (S.N. 590068— ) see Monitor Display always mean a clutch pack is leaking. Low
Unit—Normal Display and see Monitor Display voltage to a proportional solenoid or a plugged
Unit—Main Menu—Diagnostics—Transmission. orifice in the modulation circuit can also cause
(Operator’s Manual.) Or use Service ADVISOR low pressure. The modulation circuit uses
application Transmission Pressure Test template. reduced main pressure and is not affected by
See SERVICE ADVISOR System Computer clutch leakage.
Connection for information on connecting to
J-Series loaders (S.N. 590068— ). 7. Compare pressures to specifications.
3. Perform Transmission Oil Warm-Up Procedure in Analyze test results as follows:
this group.
• There should be some modulation when shifting
NOTE: Record pressures at both engine speeds. gears, but since the transmission control unit
9020
25 varies the clutch modulation according to a
12 4. Operate engine at both engine speed test number of load and speed factors, there is no
specifications. Pressure may be slightly lower at specified modulation of the clutches.
slow idle. • If a given clutch pressure is much lower than the
other clutch pressures and system pressure,
Specification
Engine—Speed ..................................................................... 1500 rpm
probable cause is the modulation circuit for that
Engine—Speed ...................................................................... Slow Idle particular clutch. See Electrical Component
Specifications (S.N. —590067). (Group
NOTE: Transmission auto mode and clutch cut-off 9015A-20.)
must be turned off. • If pressure is low at both speeds, check for
control valve problem. See Transmission Control
5. Apply service brakes and shift through all forward Valve Remove and Install. (Group 0360.)
and reverse gears. The engagement pressure for • If low pressure at slow idle and not at 1500 rpm,
each clutch should be the same. If pressure is low the clutch is leaking. Replace clutch pack. See
at slow idle and not at 1500 rpm, the clutch is Transmission Remove and Install. (Group 0300.)
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page BT40170,0000096 –19–03DEC03–3/4

092005
PN=652
Tests
TEST RESULTS
Gear Test Points Pressure
1 Forward 9
7
2 Forward 9
10
3 Forward 9
8
4 Forward 5
8
1 Reverse 6
7
2 Reverse 6
10
3 Reverse 6
8
BT40170,0000096 –19–03DEC03–4/4
9020
25
13
Transmission Element Leakage Test
The purpose of this test is to help isolate leakage in an

element as compared to other elements (clutch packs).
The pressure created by the converter-out lube flow
through the cooler is measured. Changes in cooler
pressure is a direct result of changes in lube flow.
SPECIFICATIONS
Engine Speed 1500 rpm
Converter-Out Maximum 28 kPa
Pressure Difference 0.28 bar
4 psi
ESSENTIAL TOOLS
JT05491 Connector (7/16 - 20 M 37° x 14 M x 1.5 ORB)

Continued on next page BT40170,00000A5 –19–11DEC03–1/3

092005
PN=653
Tests
9020
25
14
–19–19FEB97
T107136
2—Converter-In Pressure 6—Reverse Clutch (with quick 9—Clutch Forward Low Range Cooler
3—Regulated Reduced coupler) (with quick coupler) 12—Connection to Oil Cooler
Pressure 7—Clutch K1 (with quick 10—Clutch K2 (with quick 13—Converter-Out Pressure
4—Plug Connection for coupler) coupler)
Hydraulic Control Unit
NOTE: Four quick couplers are supplied to points on may be removed and installed into points
the transmission for checking pressure. being tested.
through John Deere Parts or existing couplers 1. Connect gauge to test port (13).

092005
PN=654
Tests
2. Use the monitor or SERVICE ADVISOR™ NOTE: Converter-out pressure will be less with
application to read engine rpm and transmission oil transmission in neutral, than with the elements
temperature. engaged. This is due to the normal leakage
that occurs in the transmission control valve
Machines (S.N. —590067) use Monitor Display Unit when all the elements are disengaged.
temperature. See Monitor Display Unit—Diagnostics 5. Maintain specified engine speed and temperature.
Menu (S.N. —590067), Transmission Sensors (d
05). (Group 9015A-15.) Or access Transmission Specification
Element Leakage Test Service ADVISOR system Converter-Out—Maximum
Pressure Difference .................................................................. 28 kPa
template. See Service ADVISOR System Computer 0.28 bar
Connection for information on connecting to 4 psi
J-Series loaders (S.N. —590067).
6. With clutch cut-off turned off and service brakes
Machines (S.N. 590068— ) see Monitor Display applied, shift through all forward and reverse gears.
Unit—Normal Display and see Monitor Display Record converter-out pressure for each gear.
Unit—Main Menu—Diagnostics—Transmission.
(Operator’s Manual.) Or use Service ADVISOR Analyze test results as follows:
application Transmission Element Leakage Test
template. See SERVICE ADVISOR System • There should be little or no pressure difference
Computer Connection for information on connecting between gears if there is no leakage in the
to J-Series loaders (S.N. 590068— ). elements that are engaged.
• If there is a pressure drop in one or more gears,
3. Perform Transmission Oil Warm-Up Procedure in element leakage is indicated. Use the
this group. Transmission Clutch Engagement And Solenoids
Activated chart to identify the element that is
4. Operate engine at test specification with common to gears showing a pressure drop. If the 9020
transmission in neutral. pressure difference is greater than specified, 25
repair the transmission. 15
Specification
Engine—Speed ..................................................................... 1500 rpm
SERVICE ADVISOR is a trademark of Deere & Company BT40170,00000A5 –19–11DEC03–3/3
Lube Pressure Test

Transmission Lube Pressure 50—150 kPa Barb Tee Fitting (1 in.)
0.5—1.5 bar
Test Hose (1 in. x 4 in.)
7—22 psi

092005
PN=655
Tests
1. Remove return hose (2) from bypass valve (1). Make

connections to gauge using test hose (3) and barb tee
fitting.
2. Use the monitor or SERVICE ADVISOR™ application

to read engine rpm and transmission oil temperature.
Machines (S.N. —590067) use Monitor Display Unit

–UN–27OCT03
Menu (S.N. —590067), Transmission Sensors (d 05).
(Group 9015A-15.) Or access Transmission Oil Tests
Service ADVISOR system template. See Service
T195753C
ADVISOR System Computer Connection for
information on connecting to J-Series loaders (S.N. —
590067).
1—Thermal Bypass Valve
Machines (S.N. 590068— ) see Monitor Display Unit— 2—Return Hose
3—Test Hose
Normal Display and see Monitor Display Unit—Main
Menu—Diagnostics—Transmission. (Operator’s
Manual.) Or use Service ADVISOR application
Transmission Pressure Test template. See SERVICE
information on connecting to J-Series loaders (S.N.
590068— ).

9020
25 group.
16
4. Operate engine at fast idle with transmission in neutral.
5. Record transmission lube pressure.
Specification
Transmission Lube—Pressure .............................................. 50—150 kPa
0.5—1.5 bar
7—22 psi
Low lube pressure can be caused by:
• Hose pinched or restricted. Inspect hoses. See

Power Train Component Location. (Group 9020-15.)
• Converter relief valve stuck open. Perform Converter
Relief Pressure Test in this group.
• Thermal bypass valve restriction. Disassemble and
inspect components.
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page BT40170,00000A7 –19–11DEC03–2/3

092005
PN=656
Tests
• Transmission pump worn. Perform Transmission Pump

Flow Test in this group.
• Suction screen plugged. Check condition of
transmission filter. Transmission pump may be noisy if
transmission suction screen is clogged. Drain
transmission. Clean transmission pump suction screen.
See Transmission Remove and Install. (Group 0300.)
BT40170,00000A7 –19–11DEC03–3/3
Differential Lock Pressure Test

Differential Lock Pressure 4102—4516 kPa Gauge 6900 kPa (69 bar) (1000 psi)
41—45 bar
595—655 psi
ESSENTIAL TOOLS
38H1273 Union (-4 M ORFS)
JTO3455 Adapter (7/16-20 M JIC X -4 F ORFS)
38H1414 (Parker No. 4FNL-S) Cap (-4)
9020
25
17
Continued on next page TX,25,WW2320B –19–12DEC03–1/3

092005
PN=657
Tests
–UN–09DEC96
T103067
9020
A—38H1273 Union (-4 M B—JT03455 Adapter (7/16-20 C—38H1414 Cap (-4) (Parker
25
ORFS) M JIC X -4 F ORFS) No. 4FNL-S)
18
NOTE: The differential lock uses pressure oil from the 3. Perform Hydraulic Oil Warm-Up Procedure. (Group
pilot control circuit. 9025-25.)
There is no leakage test. Any internal leakage 4. Start engine and operate at slow idle.
will flow into the axle sump and increase the
oil level until there is leakage at the axle vent. 5. Push differential lock switch.
Oil coming out of the vent is the result of
differential lock and (or) brake leakage. 6. Pressure must reach test specification.
1. Connect test gauge to differential lock line at axle. Specification

Differential Lock—Pressure ...................................... 4102—4516 kPa
41—45 bar
2. Use the monitor or SERVICE ADVISOR™ 595—655 psi
application to read engine rpm and hydraulic oil
temperature. See Monitor Display Unit—Normal • If pressure is not within specification and machine
Display and Monitor Display Unit—Main Menu— is equipped with dual differential locks, remove
Diagnostics—Hydraulic. (Operator’s Manual.) Or and cap differential lock pressure hose for
use Service ADVISOR application Differential Lock differential lock not being tested.
Pressure Test template. See SERVICE ADVISOR Repeat steps 4—6 to determine if differential lock
System Computer Connection for information on not being tested is leaking.
connecting to J-Series loaders (S.N. 590068— ).
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page TX,25,WW2320B –19–12DEC03–2/3

092005
PN=658
Tests
• If pressure is then within specification, differential • If pressure still is not within specification, see
lock not being tested is leaking. Repair as Pressure Reducing Valve Pressure Test. (Group
necessary. 9025-25.)
TX,25,WW2320B –19–12DEC03–3/3
Converter—In Pressure Test
SPECIFICATIONS ESSENTIAL TOOLS

Engine Speed 1500 rpm Connector (7/16 M 37° x M10 x 1) (Parker No. 4-M10x1 F80X-S)
Converter—In Minimum 276 kPa Gauge 1000 kPa (10 bar) (150 psi)
Pressure 2.8 bar
40 psi
Continued on next page CED,TX13067,52 –19–01FEB01–1/3
9020
25
19

092005
PN=659
Tests
9020
25
20
–19–19FEB97
T107136
1. Remove transmission control valve test plug and

make test connection to (2).
Continued on next page CED,TX13067,52 –19–01FEB01–2/3

092005
PN=660
Tests
2. Use the monitor or SERVICE ADVISOR™ 4. Run engine at specified test speed with
application to read engine rpm and transmission oil transmission in neutral. Record converter—in
temperature. pressure.
Machines (S.N. —590067) use Monitor Display Unit Specification

Diagnostic Mode (d 051) to display transmission Engine—Speed ..................................................................... 1500 rpm
Converter—In—Minimum
temperature. See Monitor Display Unit—Diagnostics Pressure ................................................................................ 276 kPa
Menu (S.N. —590067), Transmission Sensors (d 2.8 bar
05). (Group 9015A-15.) Or access Transmission Oil 40 psi
Tests Service ADVISOR system template. See
Service ADVISOR System Computer Connection Low converter—in pressure can be caused by:
for information on connecting to J-Series loaders
(S.N. —590067). • Converter minimum pressure regulator valve set
too low, stuck open, or spring broken or weak.
Machines (S.N. 590068— ) see Monitor Display • Transmission pump worn. Perform Transmission
Unit—Normal Display and see Monitor Display Pump Flow Test in this group.
Unit—Main Menu—Diagnostics—Transmission. • Control valve or valve gasket leakage. Remove
(Operator’s Manual.) Or use Service ADVISOR and inspect. See Transmission Control Valve
application Transmission Pressure Test template. Remove and Install. (Group 0360.)
See SERVICE ADVISOR System Computer • Converter relief valve set too low, stuck open, or
Connection for information on connecting to spring broken or weak. Perform Converter Relief
J-Series loaders (S.N. 590068— ). Pressure Test in this group.

this group.
9020
25
21
SERVICE ADVISOR is a trademark of Deere & Company CED,TX13067,52 –19–01FEB01–3/3
Converter—Out Pressure Test

Engine Speed 1500 rpm JT05491 Quick Coupler (7/16 M 37° x 14 M - 1.5 ORB)
Converter—Out Pressure 250—600 kPa
2.5—6.0 bar SERVICE EQUIPMENT AND TOOLS
36—86 psi
Continued on next page BT40170,000009A –19–05DEC03–1/3

092005
PN=661
Tests
9020
25
22
–19–19FEB97
T107136
1. Connect gauge to test port (13).
Continued on next page BT40170,000009A –19–05DEC03–2/3

092005
PN=662
Tests
2. Use the monitor or SERVICE ADVISOR™ Specification

Converter—Out—Pressure ........................................... 250—600 kPa
application to read engine rpm and transmission oil
2.5—6.0 bar
temperature. 36—86 psi
Machines (S.N. —590067) use Monitor Display Unit Low converter-out pressure can be caused by:
temperature. See Monitor Display Unit—Diagnostics • Control valve or valve gasket leakage. Remove
Menu (S.N. —590067), Transmission Sensors (d and inspect. See Transmission Control Valve
05). (Group 9015A-15.) Or access Transmission Oil Remove and Install. (Group 0360.)
Tests Service ADVISOR system template. See • Converter relief valve set too low, stuck open, or
Service ADVISOR System Computer Connection spring broken or weak. Perform Converter Relief
for information on connecting to J-Series loaders Pressure Test in this group.
(S.N. —590067). • Transmission pump worn. Perform Transmission
Pump Flow Test in this group.
Machines (S.N. 590068— ) see Monitor Display • Torque converter leakage. Disassemble and
Unit—Normal Display and see Monitor Display inspect. Perform Torque Converter and Housing
Unit—Main Menu—Diagnostics—Transmission. Remove and Install. (Group 0350.)
(Operator’s Manual.) Or use Service ADVISOR • Suction screen plugged. Check condition of
application Transmission Pressure Test template. transmission filter. Transmission pump may be
See SERVICE ADVISOR System Computer noisy if transmission suction screen is clogged.
Connection for information on connecting to Drain transmission. Clean transmission pump
J-Series loaders (S.N. 590068— ). suction screen. See Transmission Remove and
this group. High converter-out pressure can be caused by:
4. Operate engine at specified speed with • Hose pinched or restricted. Inspect hoses. See 9020
transmission in neutral. Power Train Component Location. (Group 25
9020-15.) 23
Specification
Engine—Speed ..................................................................... 1500 rpm
• Thermal bypass valve restriction. Disassemble
and inspect components.
5. Record converter—-out pressure.
SERVICE ADVISOR is a trademark of Deere & Company BT40170,000009A –19–05DEC03–3/3

092005
PN=663
Tests
Converter Relief Pressure Test
SPECIFICATIONS IMPORTANT: Do not heat transmission with cooler

Converter Relief Pressure 850—1050 kPa flow dead headed to gauge.
8.5—10.5 bar Transmission damage can occur
125—155 psi
from overheating.
NOTE: Perform this test only if machine fails
38H1150 Plug (-16 ORFS) Converter—Out Pressure Test in this group.
Adapter (7/16 M 37° x -16 ORFS)
Quick Coupler (7/16 F 37°) 1. Perform Transmission Oil Warm-Up Procedure in
Gauge 2000 kPa (20 bar) (300 psi) this group.
Continued on next page BT40170,000009B –19–05DEC03–1/3
9020
25
24

092005
PN=664
Tests
2. Remove thermal bypass valve from elbow (1).
3. Install plug (4), adapter (2), and quick coupler (3) with
gauge as shown.

–UN–28OCT03
T195782B
(Group 9015A-15.) Or access Transmission Oil Tests
Service ADVISOR system template. See Service
ADVISOR System Computer Connection for 1—Elbow (to bypass valve)
information on connecting to J-Series loaders (S.N. — 2—Adapter
590067). 3—Quick Coupler
4—Plug
Machines (S.N. 590068— ) see Monitor Display Unit—
590068— ).
9020
5. Operate engine at slow idle. 25
25
6. Record converter relief pressure.
Specification
Converter Relief—Pressure............................................... 850—1050 kPa
8.5—10.5 bar
125—155 psi
Low converter relief valve pressure can be caused by:
• Transmission control valve or gasket leakage. See

Transmission Control Valve Remove and Install.
(Group 0360.)
• Torque converter leakage. Disassemble and inspect.
Perform Torque Converter and Housing Remove and
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page BT40170,000009B –19–05DEC03–2/3

092005
PN=665
Tests
• Converter relief valve stuck open or spring broken or

weak. Remove transmission control valve and manifold
plate for access. See Transmission Control Valve
Remove and Install. (Group 0360.)
BT40170,000009B –19–05DEC03–3/3
Converter—Out Flow Test

Engine Speed 1500 rpm 38H1281 Union (-16 M ORFS x -16 M ORFS) (Parker No.
Flow Minimum Flow 50 L/min 16HLO-S)
13 gpm JT7148 Flow Meter
Continued on next page TX,9020,ME473 –19–01FEB01–1/3
9020
25
26

092005
PN=666
Tests
1. Remove thermal bypass valve (4) from elbow (1).
2. Install union (3) and test hose (2).
3. Install test hose (5).

–UN–04NOV03
T196090B
(Group 9015A-15.) Or access Converter-Out Pressure
Test Service ADVISOR system template. See Service
information on connecting to J-Series loaders (S.N. — 1—Elbow (to bypass valve)
590067). 2—Thermal Bypass Valve-to-Flow Meter Test
Hose
3—Union
Machines (S.N. 590068— ) see Monitor Display Unit— 4—Thermal Bypass Valve
Normal Display and see Monitor Display Unit—Main 5—Flow Meter-to-Elbow Test Hose
Converter—Out Flow Test template. See SERVICE
590068— ).
9020
25
IMPORTANT: Before starting engine, check that flow 27
meter loading valve is open. Pump can
be damaged if engine is started with
loading valve closed.

group.
6. Operate engine at test specification.
Specification
Engine—Speed ........................................................................... 1500 rpm
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page TX,9020,ME473 –19–01FEB01–2/3

092005
PN=667
Tests
NOTE: New machine minimum flow will be higher than

the minimum specification.
If converter-out flow is low in one gear, check for

piston or sealing ring leakage in the elements for
that gear.
7. Measure converter—out flow in each gear.
Specification
Flow—Minimum Flow ................................................................... 50 L/min
13 gpm
If converter—out flow is low in all gears, check the

following:
• Low oil level in transmission.

• Cold transmission oil.
• Air leak in pump suction tube.
• Plugged thermal bypass valve or lube passage.
Perform Lube Pressure Test in this group.
• Low transmission pump flow. Perform Transmission
Pump Flow Test in this group.
• Converter relief valve stuck open or spring weak or
broken. Perform Converter Relief Pressure Test in
this group.
• Transmission control valve gasket leakage. Remove
9020 and inspect gasket. See Transmission Control Valve
25 Remove and Install. (Group 0360.)
28
• Plugged suction screen. Clean transmission pump
suction screen. See Transmission Remove and
• Torque converter leakage. See Torque Converter
And Housing Remove and Install. (Group 0350.)
TEST RESULTS
Gear Flow
1st Forward
2nd Forward
3rd Forward
4th Forward
1st Reverse
2nd Reverse
3rd Reverse
TX,9020,ME473 –19–01FEB01–3/3

092005
PN=668
Tests
Torque Converter Stall Speed Test
SPECIFICATIONS 3. Perform Transmission Oil Warm-Up Procedure in

644J this group and Hydraulic Oil Warm-Up Procedure.
Torque Converter Stall No. 1 2100—2200 rpm (Group 9025-25.)
Fuel Speed
Torque Converter Stall No. 2 2100—2200 rpm 4. Deactivate proportional fan drive before performing
Fuel Speed test.
724J
Torque Converter Stall No. 1 2140—2160 rpm Machines (S.N. —590067) set fan to maximum
Fuel Speed speed. See Monitor Display Unit—Diagnostics
Torque Converter Stall No. 2 2140—2160 rpm Menu (S.N. —590067), Hydraulic Sensors (d 06).
Fuel Speed (Group 9015A-15.)
1. Determine what type of fuel is in fuel tank. Machines (S.N. 590068— ) set fan speed to 100%
by accessing Machine Config under Main Menu in
NOTE: Number 2 (No. 2) fuel produces more power the CAN Monitor Unit (CMU). See CAN Monitor
than number 1 (No. 1) and will impact engine Unit (CMU) Circuit Theory of Operation (S.N.
performance. 590068— ). (Group 9015B-15.)
2. Use the monitor or SERVICE ADVISOR™ NOTE: Transmission auto mode and clutch cut-off
application to read hydraulic and transmission oil must be turned off.
temperatures and engine rpm.
5. Apply service brakes and release park brake.
Diagnostic Mode to display hydraulic and 6. Operate engine at fast idle with transmission in third
transmission oil temperatures. See Monitor Display forward.
9020
Unit—Diagnostics Menu (S.N. —590067), 25
Transmission Sensors (d 05) and Hydraulic 7. Record engine speed while stalling torque 29
Sensors (d 06). (Group 9015A-15.) Or access converter. Check recorded speed against
Torque Converter Input Stall Speed Service specification.
ADVISOR system template. See Service ADVISOR
644J—Specification
System Computer Connection for information on Torque Converter Stall No. 1
connecting to J-Series loaders (S.N. —590067). Fuel—Speed ............................................................. 2100—2200 rpm
Torque Converter Stall No. 2
Machines (S.N. 590068— ) see Monitor Display Fuel—Speed ............................................................. 2100—2200 rpm
Unit—Normal Display, Monitor Display Unit—Main
Menu—Diagnostics—Transmission, and Monitor 724J—Specification
Torque Converter Stall No. 1
Display Unit—Main Menu—Diagnostics—Hydraulic. Fuel—Speed ............................................................. 2140—2160 rpm
(Operator’s Manual.) Or use Service ADVISOR Torque Converter Stall No. 2
application to access Torque Converter Stall Speed Fuel—Speed ............................................................. 2140—2160 rpm
Test template. See SERVICE ADVISOR System
Computer Connection for information on connecting If engine rpm is excessively low:
to J-Series loaders (S.N. 590068— ).
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page BT40170,000009C –19–09DEC03–1/2

092005
PN=669
Tests
• If input shaft speed reads zero rpm when torque Machines (S.N. 590068— ) view TC Output
converter is in stalled condition, the connectors Speed on CMU. See Monitor Display Unit—Main
for torque converter input speed sensor (B28) Menu—Diagnostics—Transmission. (Operators
and torque converter output speed sensor (B29) Manual.)
may be reversed. Switch sensor connectors and Torque converter output speed should be
verify engine speed with torque converter stalled. approximately engine speed when in neutral. It
• If low engine horsepower is suspected, perform must go to 0 rpm when torque converter is
Engine Power Test Using Turbocharger Boost stalled. If output speed reads anything above
Pressure. (Group 9010-25.) zero rpm, the transmission is slipping. See
• Incorrect torque converter—in and or converter— Diagnose Transmission System Malfunctions.
out pressures. Perform Converter—In Pressure (Group 9020-15.)
Test and Converter—Out Pressure Test in this • Incorrect torque converter—in and or converter—
group. out pressures. Perform Converter—In Pressure
• Incorrect torque converter or torque converter Test and Converter—Out Pressure Test in this
failure. Remove and replace torque converter. group.
See Torque Converter And Housing Remove and • Incorrect torque converter or torque converter
Install. (Group 0300.) failure. Remove and replace torque converter.
See Torque Converter And Housing Remove and
If engine rpm is excessively high: Install. (Group 0300.)
• Clutch slippage may be indicated. 8. After testing torque converter stall, cycle key switch
Machines (S.N. —590067) press NEXT on to restart engine. This will activate proportional fan
monitor until (d 054) Torque Output Speed is drive.
displayed.
9020
25
30
BT40170,000009C –19–09DEC03–2/2
Transmission Oil Cooler Thermal Bypass Valve Temperature Test

Thermal Bypass Valve Start to 79—85°C Test Hose (1 in. x 2 ft)
Open Temperature 175—185°F
Barb Fitting—Straight (1 in.)
Thermal Bypass Valve Full 96°C
JT7148 Flow Meter
Open Temperature 205°F
Temperature Reader
Continued on next page BT40170,000009D –19–09DEC03–1/2

092005
PN=670
Tests
–UN–25NOV03
T196597
T196597
9020
1—Thermal Bypass 2—Elbow
25
Valve-to-Oil Cooler
31
Hydraulic Hose
NOTE: If an oil cooler bypass valve malfunction is starts to increase. Compare temperature to
suspected, the thermal bypass valve can be specification.
removed and inspected in less time than it
takes to perform a test. Specification
Thermal Bypass Valve Start to
Open—Temperature ............................................................. 79—85°C
1. Disconnect hose (1) at elbow (2). 175—185°F
2. Connect flow meter inline with test hose and barb 6. Observe temperature at which flow meter reading is
fitting. at maximum flow.
3. Install temperature reader at flowmeter. Specification
Thermal Bypass Valve Full
IMPORTANT: Before starting engine, check that Open—Temperature .................................................................... 96°C
flow meter loading valve is open. 205°F
Pump can be damaged if engine is
started with loading valve closed. 7. If valve does meet specifications, remove and
repair valve. Repeat test after repairing valve.
4. Start engine.
5. Perform Transmission Oil Warm-Up Procedure and

observe temperature at which flow meter reading
BT40170,000009D –19–09DEC03–2/2

092005
PN=671
Tests
Transmission Oil Cooler Thermal Bypass Valve Pressure Test

Transmission Oil Cooler 214—269 kPa Gauge 700 kPa (7 bar) (100 psi) (2 used)
Thermal Bypass Valve 2.1—2.7 bar
Barb Fitting—Straight (1 in.)
Pressure Differential 31—39 psi
Barb Fitting—Tee (1 in.)
Test Hose (1 in. x 2 ft) (2 used)
Continued on next page BT40170,000009E –19–10DEC03–1/3
9020
25
32

092005
PN=672
Tests
–UN–25NOV03
T196598
T196598
9020
1—Thermal Bypass 2—Thermal Bypass Valve
25
Valve-to-Oil Cooler Hydraulic Hose
33
Hydraulic Hose
NOTE: If an oil cooler bypass valve malfunction is temperature. See Monitor Display Unit—Diagnostics
suspected, the thermal bypass valve can be Menu (S.N. —590067), Transmission Sensors (d
removed and inspected in less time than it 05). (Group 9015A-15.) Or access Transmission Oil
takes to perform a test. Tests Service ADVISOR system template. See
1. Disconnect and plug hose (1) to cooler. Connect for information on connecting to J-Series loaders
pressure gauge to bypass valve with test hose and (S.N. —590067).
barb fitting.
Machines (S.N. 590068— ) see Monitor Display
2. Disconnect hose (2). Connect pressure gauge inline Unit—Normal Display and see Monitor Display
with return hose using test hose and barb tee Unit—Main Menu—Diagnostics—Transmission.
fitting. (Operator’s Manual.) Or use Service ADVISOR
application Transmission Pressure Test template.
3. Use the monitor or SERVICE ADVISOR™ See SERVICE ADVISOR System Computer
application to read engine rpm and transmission oil Connection for information on connecting to
temperature. J-Series loaders (S.N. 590068— ).

SERVICE ADVISOR is a trademark of Deere & Company Continued on next page BT40170,000009E –19–10DEC03–2/3

092005
PN=673
Tests
NOTE: Pressure differential should start out low. 6. Record differential pressure and compare to
When thermal bypass valve opens, pressure specification.
differential will increase.
Specification
NOTE: Observe pressure gauges during warm-up. Transmission Oil Cooler
Thermal Bypass Valve—
Pressure Differential ..................................................... 214—269 kPa
4. Perform Transmission Oil Warm-Up Procedure in 2.1—2.7 bar
this group. 31—39 psi
5. When oil temperature reaches specification, put If pressure is low:

transmission in neutral and operate engine at slow
idle. • Remove, repair, or replace valve.
BT40170,000009E –19–10DEC03–3/3
Transmission Oil Cooler Restriction Test
The purpose of this test is to check for restriction

internal to the transmission oil cooler which can cause
transmission overheating.
9020
25 SPECIFICATIONS
34
Maximum Differential 276 kPa
(inlet-to-outlet) Pressure 2.8 bar
40 psi

38H1419 (-16 F ORFS) (Parker No. 16 FNL-S) Cap
Barb Tee Fitting (1 in.) (2 used)
Test Hose (1 in. x 2 ft) (2 used)
JT03460 (7/16 -20 M 37° x -16 F ORFS) Quick Coupler (2 used)
JT02156A Digital Pressure and Temperature Analyzer
JT05746 Portable Filter Caddy
Continued on next page BT40170,000009F –19–11DEC03–1/3

092005
PN=674
Tests
–UN–12DEC03
3
1
T196871
T196871
9020
1—Elbow 2—Bypass Valve-to-Oil Cooler 3—Oil Cooler-to-Bypass Valve
25
Hydraulic Hose Hydraulic Hose
35
NOTE: If an internally restricted oil cooler is Temperature Analyzer Installation procedure.

suspected, the cooler can be backflushed in (Group 9025-25.)
less time than it takes to run this test. Use
filter caddy to backflush. 4. Use the monitor or SERVICE ADVISOR™
application to read engine rpm and transmission oil
1. Remove bypass valve from elbow (1). Remove temperature.
hose (2) from valve. Cap port on valve where hose
(2) was removed. Connect inline between hose (2) Machines (S.N. —590067) use Monitor Display Unit
and elbow (1) using barb tee fitting and test hose. Diagnostic Mode (d 051) to display transmission
2. Remove hose (3) at bypass valve. Connect inline Menu (S.N. —590067), Transmission Sensors (d
between hose (3) and valve using barb tee fitting 05). (Group 9015A-15.) Or access Transmission Oil
and test hose. Tests Service ADVISOR system template. See
3. Install JT02156A Digital Pressure Analyzer with for information on connecting to J-Series loaders
1000 psi pressure transducers to both tees to read (S.N. —590067).
pressure differential. Perform Digital Pressure And
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page BT40170,000009F –19–11DEC03–2/3

092005
PN=675
Tests
Machines (S.N. 590068— ) see Monitor Display Unit— Specification

Maximum Differential
(inlet-to-outlet)—Pressure ....................................................... 276 kPa
Menu—Diagnostics—Transmission. (Operator’s 2.8 bar
Manual.) Or use Service ADVISOR application 40 psi
ADVISOR System Computer Connection for If difference is greater than specification:
590068— ). • Backflush oil cooler using a filter caddy.
5. Perform Transmission Oil Warm-Up Procedure in If cooler does not meet specifications after
this group. backflushing:
6. Operate engine at fast idle. • Replace cooler.
7. Read pressure on inlet and outlet sides of oil cooler

and compare to specification.
BT40170,000009F –19–11DEC03–3/3
Axle Circulation Dual Pump Flow and

Temperature Tests
The purpose of this test is to verify that the axle

circulation motor and dual pump assembly is functioning
9020 properly keeping axle oil temperatures within normal
25
operating range.
36
SPECIFICATIONS
Axle Oil Temperature 49°C
120°F
Axle Circulation Pump Flow Rate 3.8 L/min
Minimum (one pump) 1.0 gpm

JT05800 Digital Thermometer
-6 Test Hose with -6 ORFS End

092005
PN=676
Tests
–UN–13NOV03
T196291
3
T196291
9020
1—Motor Outlet-to-Reservoir 2—Pump Inlet 3—Pump Outlet
25
37
1. Warm axle to operating temperature. 4. Operate engine at slow idle and hold bucket in roll
back over relief. Record flow through axle
2. Record temperature at which axle oil stabilizes circulation dual pump.
during operation. Perform Digital Pressure And
Temperature Analyzer Installation procedure. Specification
(Group 9025-25.) Axle Circulation Pump—Flow
Rate Minimum (one pump) ................................................... 3.8 L/min
1.0 gpm
Specification
Axle Oil—Temperature ................................................................ 49°C
120°F
3. Install test hose between one axle circulation pump

outlet (3) and clean container. Check both pumps
individually.
BT40170,00000A0 –19–11DEC03–2/2

092005
PN=677
Tests
Axle Circulation Motor Flow Test
The purpose of this test is to determine axle circulation

motor flow rate and performance.
SPECIFICATIONS
Axle Motor Flow Rate Minimum 1.9 L/min
0.50 gpm

-6 Test Hose with -6 ORFS End
9020
25
38

092005
PN=678
Tests
–UN–13NOV03
T196291
3
T196291
9020
25
39
1. Install test hose between motor outlet (1) and clean Specification
Axle Motor—Flow Rate
container.
Minimum ............................................................................... 1.9 L/min
0.50 gpm
2. Operate engine at slow idle and record axle motor
flow rate. Compare rate to specification.
BT40170,00000A1 –19–11DEC03–2/2
Axle Breather Test
The purpose of this test is to check that the axle breather

opens allowing pressure relief within the axle housing.
SPECIFICATIONS
Axle Breather Pressure Rating 35—49 kPa
0.35—0.49 bar
5—7 psi

092005
PN=679
Tests
NOTE: If axle level is low and/or leaking from outer axle

seals, cause could be a plugged breather.
1. Assure correct breather is in axle, pressure rating is

stamped on top of the breather.
–UN–27AUG98
2. Measure axle internal pressure by installing a gauge in
the fill port.
3. Operate machine to warm axle to normal temperature.
T116846B
Specification
Axle Breather—Pressure Rating ............................................. 35—49 kPa
0.35—0.49 bar
5—7 psi
Pressure may exceed specification by 2 psi and not be

excessive.
If pressure is within specification:
• Breather is ok, inspect and repair outer axle seals.
If pressure is greater than specification:
• Clean or replace breather.
9020
25
40
BT40170,00000A2 –19–11DEC03–2/2
Axle Circulation Pump Inlet Suction Check
The purpose of this test is to determine if the axle housing

suction screen is clogged and axle circulation pumps are
functioning properly.
SPECIFICATIONS
Axle Circulation Pump Inlet 1.7 kPa
Vacuum Maximum Allowable 170 mbar
5 in. HG

092005
PN=680
Tests
–UN–13NOV03
T196291
3
T196291
9020
25
41
1. Install a tee between pump inlet line (2) and pump. If vacuum is zero:
Connect a vacuum gauge to tee. • Pump or motor may not be turning. Replace
motor and dual pump assembly if necessary.
2. Start machine and operate at slow idle, hold bucket
in roll back over relief. If vacuum is above specification:
Record vacuum. • Suction screen is clogged. Clean debris from

screen.
Specification
Axle Circulation Pump Inlet—
Vacuum Maximum Allowable .................................................. 1.7 kPa
170 mbar
5 in. HG
BT40170,00000A3 –19–11DEC03–2/2

092005
PN=681
Tests
9020
25
42

092005
PN=682
Section 9025
Hydraulic System
Contents
Page Page
Group 05—Theory Of Operation Bucket Section Operation—Tool Carrier . . .9025-05-51

Loader Hydraulic System . . . . . . . . . . . . . . .9025-05-1 Outlet Section Operation . . . . . . . . . . . . . . .9025-05-53
Hydraulic Pump Operation . . . . . . . . . . . . . .9025-05-4 Load Sense Circuit—Steering . . . . . . . . . . .9025-05-55
Hydraulic Pump Control . . . . . . . . . . . . . . . .9025-05-5 Load Sense Circuit—Steering And Boom
Hydraulic Pump Control—Neutral . . . . . . . . .9025-05-6 Down . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-57
Hydraulic Pump Control—Function Load Sense Circuit—Boom Raise And Bucket
Metering . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-8 Dump. . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-59
Hydraulic Pump Control—Full Flow . . . . . . .9025-05-10 Load Sense Relief Valve Operation. . . . . . .9025-05-60
Hydraulic Pump Control—Function Relief Valve Operation . . . . . . . . . . . . . . . .9025-05-61
Bottomed . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-12 Circuit Relief Valve Operation . . . . . . . . . . .9025-05-62
Fan Drive Operation . . . . . . . . . . . . . . . . . .9025-05-13 Anti-Cavitation Valve Operation. . . . . . . . . .9025-05-65
Steering System Components . . . . . . . . . . .9025-05-14 Return Filter Operation . . . . . . . . . . . . . . . .9025-05-66
Steering Valve Operation . . . . . . . . . . . . . .9025-05-15 Ride Control Operation . . . . . . . . . . . . . . . .9025-05-70
Secondary Steering Inlet Manifold
Operation. . . . . . . . . . . . . . . . . . . . . . . . .9025-05-17 Group 15—Diagnostic Information
Secondary Steering System Operation . . . .9025-05-18 Hydraulic Circuit Symbols . . . . . . . . . . . . . . .9025-15-1
Pressure Reducing Valve—Boom Raise Hydraulic System Schematics . . . . . . . . . . . .9025-15-2
Operation (S.N. —590067) . . . . . . . . . . .9025-05-19 Hydraulic System Component Location . . . . .9025-15-8
Pressure Reducing Valve—Boom Diagnose Hydraulic System
Down—Engine Running Operation (S.N. — Malfunctions . . . . . . . . . . . . . . . . . . . . . .9025-15-15
590067) . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-21
Pressure Reducing Valve—Boom Group 20—Adjustments
Down—Engine OFF Operation (S.N. — Hydraulic Oil Clean-Up Procedure Using
590067) . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-23 Portable Filter Caddy . . . . . . . . . . . . . . . . .9025-20-1 9025
Pressure Reducing Valve Operation (S.N. Return-To-Dig Adjustment . . . . . . . . . . . . . . .9025-20-2
590068— ). . . . . . . . . . . . . . . . . . . . . . . .9025-05-25 Return-To-Carry and Boom Height Kickout
Service Brake Hydraulic System . . . . . . . . .9025-05-26 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . .9025-20-2
Service Brake Accumulator . . . . . . . . . . . . .9025-05-27 Pump Load Sense Differential and Standby
Service Brake Valve . . . . . . . . . . . . . . . . . .9025-05-28 Pressure Adjustment . . . . . . . . . . . . . . . . .9025-20-2
Pin and Axle Disconnect Operation . . . . . . .9025-05-30 Pilot Controller Adjustment—Two Lever
Pilot Control Lever Operation (S.N. — Pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-20-2
590067) . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-30 Ride Control Accumulator Hydraulic
Pilot Control Lever Operation (S.N. Discharge . . . . . . . . . . . . . . . . . . . . . . . . .9025-20-3
590068— ). . . . . . . . . . . . . . . . . . . . . . . .9025-05-36 Charge Ride Control Accumulator . . . . . . . . .9025-20-4
Pilot Orifice Check Valve For Control Valve Auxiliary Valve Section—Stroke
Sections. . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-38 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . .9025-20-7
Loader Control Valve . . . . . . . . . . . . . . . . .9025-05-40
Boom Section—Boom Down And Group 25—Test
Steering . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-42 Hydraulic Oil Warm-Up Procedure. . . . . . . . .9025-25-1
Boom Section—Boom Raise And Bucket Digital Pressure And Temperature Analyzer
Dump. . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-44 Installation . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-1
Bucket Section—Boom Raise and Bucket Fan Pump Pressure Test . . . . . . . . . . . . . . .9025-25-2
Dump. . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-46 Fan Motor Speed Test . . . . . . . . . . . . . . . . .9025-25-4
Auxiliary Section—Operating And Boom Fan Pump Flow Test . . . . . . . . . . . . . . . . . . .9025-25-5
Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-48
Auxiliary Sections—Stroke Adjusters. . . . . .9025-05-50 Continued on next page

092005
PN=1
Contents
Page
Fan Motor Case Drain Test . . . . . . . . . . . . . .9025-25-7

Pump Load Sense Differential And Standby
Pressure Test . . . . . . . . . . . . . . . . . . . . . .9025-25-9
Maximum System Pressure Test. . . . . . . . .9025-25-12
Hydraulic Pump Flow Test . . . . . . . . . . . . .9025-25-15
Hydraulic Pump Case Drain Test . . . . . . . .9025-25-17
Loader System Relief and Circuit Relief Valve
Pressure Test . . . . . . . . . . . . . . . . . . . . .9025-25-19
Loader Cylinder Drift Test . . . . . . . . . . . . . .9025-25-22
Boom, Bucket and Steering Cylinder
Leakage Test. . . . . . . . . . . . . . . . . . . . . .9025-25-24
Steering Valve Leakage Test . . . . . . . . . . .9025-25-25
Steering Valve Drift Test . . . . . . . . . . . . . . .9025-25-27
Secondary Steering Pump Relief Valve
Pressure Test . . . . . . . . . . . . . . . . . . . . .9025-25-29
Secondary Steering Manifold Primary
Check Valve Leakage Test . . . . . . . . . . .9025-25-31
Secondary Steering Manifold Secondary
Check Valve Leakage Test . . . . . . . . . . .9025-25-33
Pressure Reducing Valve Pressure Test . . .9025-25-34
Cycle Time Test . . . . . . . . . . . . . . . . . . . . .9025-25-35
Brake Accumulator Precharge Test . . . . . . .9025-25-36
Boom Down Accumulator Precharge
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-38
Brake Valve Pressure Test . . . . . . . . . . . . .9025-25-40
Brake Valve Leakage Test . . . . . . . . . . . . .9025-25-42
Brake Accumulator Inlet Check Valve
Leakage Test. . . . . . . . . . . . . . . . . . . . . .9025-25-43
Axle And Pin Disconnect Pressure Test . . .9025-25-45
Hydraulic Oil Filter Inspection Procedure. . .9025-25-46
9025

092005
PN=2
Group 05
Theory Of Operation
NOTE: See Hydraulic System Schematics, See Neutral

Hydraulic System Component Location. (Group
9025-15.) The hydraulic pump supplies a low standby pressure
to all closed center control valves. There is essentially
All the hydraulic functions are incorporated into one no flow. With the pilot enable/boom down switch in the
system utilizing a singe axial piston pump. These center on position, both the boom down and the pilot
include the loader, steering and service brake enable solenoid provides low regulated pressure to the
functions. Plus the optional differential lock, axle pilot controller. All load sense lines and passages are
disconnect, pin disconnect, ride control and oil cooler bled to return. The pin disconnect is shown in the
functions. These components are tied together by a disconnected position.
pressure flow compensating load sense system.
Steering Operation
The major components include:
When the steering valve is rotated and steering is
1. A variable displacement axial piston pump with load started, the pressure to the steering cylinders is also
sense flow and pressure control. picked up in the valve and sent out as a load sense. It
2. An orbital steering valve. is directed to both ends of the loader control valve.
3. A loader control valve with load sense, individual One path is to a shuttle check valve, through a 0.055
workport flow compensation and with a circuit in. orifice and then back to the pump. The pump goes
providing priority for steering and loader pilot control into stroke and starts suppling pressure oil to the
valve. steering valve maintaining the differential pressure
4. A pressure reducing valve module that provides low difference between load sense and output pressure.
regulated pressure for the pilot controller and the
optional differential lock, axle disconnect and pin The other path for load sense in the loader valve is to
disconnect. the spring end of each compensator valve. This will
5. A low pressure brake valve pressure limiting and have no effect on the steering circuit until one of the
modulation. loader functions is operated.
Design features include: The axle disconnect solenoid is shown in the

disconnect position which hydraulically disengages the
1. All closed center control valves front axle. 9025
2. Improved system efficiency with minimal relief flow 05
1
losses Steering and Boom Down
3. Metering independent of load
4. A single load sense circuit controlling pump flow, Both steering and boom down functions are being
providing priority to steering and proportional and operated at the same time. Without some type of flow
pressure flow compensation to all loader functions control to the boom cylinder rod ends all the pump flow
would go to the boom circuit because little or no oil
Overall System Operation: pressure is required for lowering the boom. With
relatively high pressures required for steering, there
NOTE: See Hydraulic System Component Location. would be little or no steering with this condition.
(Go to Group 9025—15.)
See Hydraulic System Schematics (Go to

Group 9025—15.)

092005
PN=685
Theory Of Operation
To provide priority for the steering circuit in this pressure from boom raise will be much higher than
situation, compensators are used in each valve that from bucket dump. It will flow through the boom
section. Load sense pressure, which will be relatively C1 check and on through C4, the orifice and then to
high, from the steering valve is directed to the spring the hydraulic pump and isolation valve. The metered
side of each compensator, thus restricting or blocking load sense from the bucket will be blocked at its C1
flow through the compensator to the boom down circuit check because of the much higher load sense
with very low pressures. Therefore, the steering circuit pressure on the other side.
will always have priority when any of the loader
functions are at a low pressure. The boom regulated load will flow through C2 to the
isolation valve end. The bucket regulated load sense
Boom Raise and Bucket Dump at low pressure will be blocked at the boom C2 check.
The regulated boom load sense will control the
When both the boom raise and bucket dump functions isolation valve output so that it is equal to the boom
are being operated at the same time, without flow regulated load sense. This pressure which is
control to the bucket dump circuit all of the pump flow essentially the boom raise work load is sent through all
would go to that function and there would be no boom C3 checks to all the compensators. Since the pump
raise. will be working against equal pressures at the
compensators, the flow will be equal to both functions,
To provide equal flow to both functions, compensators though the bucket work load pressure is much less
are used in both circuits. The metered load sense than that for the boom.
TX,9025,ME311 –19–14FEB97–2/2
9025
05
2

092005
PN=686
Theory Of Operation
9025
05
3

092005
PN=687
Theory Of Operation
Hydraulic Pump Operation
PRESSURE COMPENSATOR
C
VALVE
E CONTROL
FROM B ORIFICE D BIAS PISTON
PISTON
A LOAD SENSE STROKE
CIRCUIT F LIMITER
CONTROL
G
PISTON PIN
H SWASHPLATE
BEARING
Q
FROM I SHAFT SEAL
PUMP
OUTLET J
R RELEIF VALVE DRIVE
SHAFT
S LOAD PISTON P K BALLGUIDE

9025 SENSE ASSEMBLY
05 VALVE L SWASHPLATE
4 CYLINDER O
BLOCK
BEARING N M PISTON RETAINER
–19–25MAR97
U HIGH PRESSURE
T107770
T107770 T HYDRAULIC PUMP

V RETURN PRESSURE

092005
PN=688
Theory Of Operation
A—From Load Sense Circuit G—Control Piston Pin M—Piston Retainer S—Load Sense Valve—
B—Orifice H—Swashplate Bearing N—Bearing Differential Pressure
C—Pressure Compensator I—Shaft Seal O—Cylinder Block T—Hydraulic Pump
Valve J—Drive Shaft P—Piston Assembly U—High Pressure
D—Bias Piston K—Ball Guide Q—From Pump Outlet V—Return Pressure
E—Control Piston L—Swashplate R—Relief Valve—Low
F—Stroke Limiter Pressure Standby
The hydraulic pump is an axial piston, variable piston retainer (M) backed by a spring-loaded ball
displacement pump (T). The pump is driven by a guide holds the piston slippers against the swash plate
splined coupling on the end of the torque converter (L). As the cylinder block rotates, the pistons move in
impeller shaft. The pump drive shaft (J) is supported and out of their bores creating a pumping action. The
by a ball bearing on the splined end and a bearing cylinder block is supported by a bearing (N).
sleeve in the valve plate end cap.
The swash plate rides on a bearing and is moved by a
With the engine running, the drive shaft drives the pin (G) that moves with the pressure compensator
cylinder block (O) and 9 piston assemblies (P). A control piston.
TX,9025,ME312 –19–10AUG96–2/2
Hydraulic Pump Control
Components: • Maintains a differential pressure between pump

discharge and load sense whenever hydraulic
• Control piston functions are activated.
• Bias piston
• Load sense valve—Differential Pressure Relief valve—Low standby pressure:
• Relief valve—Low pressure standby
• Pressure compensator spool (4-way valve) • Regulates pump low pressure standby discharge in
neutral
Control piston: • Necessary to supply both the service brakes and the
9025
pilot circuit with adequate pressure 05
• Move the swash plate to increase or decrease pump 5
flow Pressure compensator spool (4-way valve)
Bias piston • Routes pump discharge pressure to the bias piston

to increase pump flow
• Works with the control piston spring to hold the • Routes pump discharge pressure to the control
control piston at a given pump flow position piston to decrease pump flow
Load sense valve—Differential pressure:
TX,9025,ME313 –19–28AUG96–1/1

092005
PN=689
Theory Of Operation
Hydraulic Pump Control—Neutral
FROM LOAD B ORIFICE C BIAS

SENSE CIRCUIT PISTON
A D CONTROL
PISTON
STROKE E
LIMITER
G PRESSURE
COMPENSATOR F PIN TO SWASH
VALVE PLATE
H FROM PUMP
OUTLET
I C
RELIEF
VALVE
J
LOAD SENSE H
VALVE G
D
9025 B
K STANDBY PRESSURE
05
6 L BIAS PRESSURE RELIEF LS VALVE
VALVE
–19–19FEB97
M CONTROL PRESSURE J
N RETURN PRESSURE I A
O HYDRAULIC PUMP CONTROL - NEUTRAL T106408

T106408
A—From Load Sense Circuit F—Pin to Swash Plate J—Load Sense Valve— M—Control Pressure
B—Orifice G—Pressure Compensator Merging Pressure N—Return Pressure
C—Bias Piston Valve K—Standby Pressure Oil O—Hydraulic Pump Control—
D—Control Piston H—From Pump Outlet L—Bias Pressure Neutral
E—Stroke Limiter I—Relief Valve—Low Standby
Pressure
When the machine is first started, the pump is at full • In neutral pump discharge pressure is at low
swash. pressure standby. This is necessary to supply both
the service brakes and the pilot circuit.
Pump pressure will continue to rise until the low
pressure standby setting is reached.

092005
PN=690
Theory Of Operation
Low pressure standby is achieved when pump • The bias piston works with the control piston spring
discharge pressure is high enough to open both the to hold the pump at full stroke until pressure rises.
load sense valve (J) and the relief valve (I) which are
in series. Pressure oil working with the spring to hold the
pressure compensator spool closed is also trying to
• The load sense valve is set at differential pressure. open the load sense valve (J).
Differential pressure is the difference between pump
output pressure and load sense pressure that will When pump discharge pressure reaches differential
open the load sense valve. In neutral load sense pressure, the load sense valve will open. Oil flowing
pressure is equal to return pressure. When operating across the load sense valve is now sensed on the
a function load sense pressure is essentially poppet of relief valve (I).
workport pressure.
• The relief valve is set to obtain low pressure Pump discharge pressure increases until relief valve
standby. opens.
• The combined setting of the two valves equals low
pressure standby. This causes a pressure drop on the spring side of the
compensator valve spool. Pump discharge pressure
Pressure oil from the pump outlet passage (H) works will move the pressure compensator valve spool
on the end of the pressure compensator valve (G) against the spring, opening a path to the large end of
spool trying to open it by pushing it against the spring. the control piston (D).
A small amount of oil flows through the center of the The bias piston cavity is open to return until the pump
pressure compensator spool and combines with the reaches the required flow.
spring force to hold the compensator spool closed.
The control piston will move to the left, destroking the
With the spool in the closed position, a passage is pump to maintain the flow required.
open which allows oil to flow to the cavity behind the
bias piston (C).
9025
05
TX,9025,ME314 –19–28AUG96–2/2
7

092005
PN=691
Theory Of Operation
Hydraulic Pump Control—Function Metering

A D CONTROL
PISTON
STROKE E
LIMITER
G PRESSURE F PIN TO SWASH

COMPENSATOR PLATE
H FROM PUMP VALVE
OUTLET
I
RELIEF C
VALVE
J
LOAD SENSE
VALVE H
G
D
9025
05 K SYSTEM PRESSURE B
8
L LOAD SENSE PRESSURE
RELIEF LS VALVE
M BIAS PRESSURE VALVE J
–19–19FEB97
N CONTROL PRESSURE I A
O RETURN PRESSURE T106410
T106410 P HYDRAULIC PUMP CONTROL - FUNCTION METERING
A—From Load Sense Circuit F—Pin to Swash Plate J—Load Sense Valve— N—Control Pressure
B—Orifice G—Pressure Compensator Differential Pressure O—Return Pressure
C—Bias Piston Valve K—System Pressure P—Hydraulic Pump Control—
D—Control Piston H—From Pump Outlet L—Load Sense Pressure Function Metering
E—Stroke Limiter I—Relief Valve—Low Standby M—Bias Pressure
Pressure
When the operator starts to move or operate a Load sense is equal to the highest workport pressure
function, the pump discharge pressure from the pump and is routed to the spring area of the load sense
outlet (H) will drop. valve (J).

092005
PN=692
Theory Of Operation
Load sense plus spring force will close the load sense When this differential pressure is reached, the load
valve until pump discharge pressure is at the sense valve and relief valve (I) will start to open
differential pressure above load sense. causing a pressure drop on the left side of the
pressure compensator spool.
With the load sense valve closed, pressure will build
on the left side of the pressure compensator valve Pump discharge pressure will move the spool to the
spool (G), causing the spool to shift momentarily to the left which blocks the path to return and traps oil in the
right. This opens a path for the some of the oil on the large end of the control piston.
large end of the control piston (D) to drain to tank.
Oil in the cavity behind the bias piston is also trapped
A small amount of pump pressure flows through the by the pressure compensator spool.
center of the pressure compensator spool and is
routed to the cavity behind the bias piston to work with The pump is being held at a fixed displacement at this
the control piston spring and bring the pump into time.
stroke.
If the operator continues to meter the function, pump

discharge will increase until it begins to open the load
sense valve.
TX,9025,ME315 –19–28AUG96–2/2
9025
05
9

092005
PN=693
Theory Of Operation
Hydraulic Pump Control—Full Flow

A D CONTROL
PISTON
STROKE E
LIMITER

COMPENSATOR PLATE
H FROM PUMP VALVE
OUTLET
I
RELIEF C
VALVE
J
LOAD SENSE
H
VALVE
G
D
9025
05 B
10
K HIGH PRESSURE
RELIEF LS VALVE
L RETURN PRESSURE VALVE J
–19–19FEB97
I A
T106409
T106409
M HYDRAULIC PUMP CONTROL - FULL FLOW
A—From Load Sense Circuit F—Pin to Swash Plate I—Relief Valve—Low Standby K—High Pressure
B—Orifice G—Pressure Compensator Pressure L—Return Pressure
C—Bias Piston Valve J—Load Sense Valve— M—Hydraulic Pump Control—
D—Control Piston H—From Pump Outlet Differential Pressure Full Flow
E—Stroke Limiter
If the operator is running several functions at one time Load sense is equal to the highest workport pressure
the flow requirements will be high and pump discharge and is routed to the spring area of the load sense
pressure from pump outlet (H) will drop. valve (J).

092005
PN=694
Theory Of Operation
Load sense plus spring force will close the load sense routed to the cavity behind the bias piston (C) to work
valve until pump discharge pressure is at differential with the control piston spring and bring the pump into
pressure above load sense. stroke.
With the load sense valve closed, pressure will build If the operator continues to run several functions at
on the left side of the pressure compensator valve one time and flow requirements are high, all of the oil
spool (G), causing the spool to shift to the right. This on the large end of the control piston will drain to tank.
opens a path for the oil on the large end of the control
piston (D) to drain to tank. The control piston will move all the way to the right
and the pump will be at full stroke.
A small amount of pump pressure flows through the
center of the pressure compensator spool and is
TX,9025,ME316 –19–28AUG96–2/2
9025
05
11

092005
PN=695
Theory Of Operation
Hydraulic Pump Control—Function Bottomed

A D CONTROL
PISTON
STROKE E
LIMITER

COMPENSATOR PLATE
H FROM PUMP VALVE
OUTLET
I
RELIEF C
VALVE
J
LOAD SENSE
VALVE H
G
D
9025
05
K SYSTEM PRESSURE
12
B
L LOAD SENSE PRESSURE
M RELIEF LS VALVE
BIAS PRESSURE
VALVE J
–19–19FEB97
N CONTROL PRESSURE
I A
O RETURN PRESSURE
T106411
T106411 P HYDRAULIC PUMP CONTROL - FUNCTION BOTTOMED
A—From Load Sense Circuit F—Pin to Swash Plate J—Load Sense Valve— N—Control Pressure
B—Orifice G—Pressure Compensator Differential Pressure O—Return Pressure
C—Bias Piston Valve K—System Pressure P—Hydraulic Pump Control—
D—Control Piston H—From Pump Outlet L—Load Sense Pressure Function Bottomed
E—Stroke Limiter I—Relief Valve—Low Standby M—Bias Pressure
Pressure

092005
PN=696
Theory Of Operation
If the operator fully actuates a function, the cylinder will This opens the bias piston (C) to return and directs
travel to the end of its stroke and load sense pressure pressure oil to the control piston (D) head end.
will continue to rise until it reaches the setting of the
load sense relief valve in the outlet section of the The control piston moves against the spring causing
loader control valve. At this point load sense pressure the pump to destroke until there is just enough flow to
is limited to this setting. Pump outlet pressure will maintain maximum system pressure. This pressure will
continue to increase until it is at the differential be equal to the setting of the load sense relief valve
pressure above load sense. At this point the load plus the differential pressure setting of the load sense
sense valve opens, flow begins through the valve.
compensator valve (G) moving it against the spring.
TX,9025,ME317 –19–28AUG96–2/2
Fan Drive Operation
(S.N. —590067) (S.N. 590068— )
The fan drive system consist of a gear type pump, a Fan pump is powered by a gear on the front of the
gear type motor with integral relief valve and plumbing engine. Pump output is directed to the fan reversing
connections to the hydraulic system. The pump is valve and motor inlet. Proportional solenoid is used to
directly driven off the front gear train of the engine. Oil control fan speed and act as an adjustable relief valve.
flow to the pump comes from the hydraulic reservoir.
Pump output is connected to the motor inlet. When the Proportional fan speed is controlled by the Flex Load
motor and fan rotate, return flow is to the hydraulic Controller (FLC) based upon machine fluid and air
system filter inlet and then to the hydraulic reservoir. temperatures. Fan speed may be manually set from
0% to 100% in increments of 10% if desired. With fan
A variable position solenoid is used to control the fan speed is set at 100% in the CAN Monitor Unit (CMU),
motor relief valve. If engine, transmission, hydraulic, proportional solenoid allows a small amount of oil from
and charge air system temperatures are cool, voltage fan pump to return to reservoir. With fan speed is set
is applied to the relief solenoid (Y37). This reduces at 0%, proportional solenoid allows a larger amount of
relief valve pressure setting which reduces fan speed. oil to return to reservoir. As fan speed setting
9025
As system heats up during normal operation the increases to 100%, proportional solenoid allows less
05
voltage applied to the solenoid decreases, the oil to return to reservoir and more oil to flow to fan 13
pressure setting increases, and causes the fan speed motor. An electrical malfunction will default fan speed
to increase. to 100% to avoid overheating.
The Engine Coolant Sensor (B1), Transmission Oil For access to fan speed settings, see CAN Monitor
Temperature Sensor (B32), Hydraulic Oil Temperature Unit (CMU) Circuit Theory of Operation (S.N.
Sensor (B15), and Intake Manifold Air Temperature 590068— ). (Group 9015B-15.)
Sensor (B7) send system temperatures to the engine
(ECU), Chassis (CCU) and transmission (TCU) Control For more electrical fan drive information, see Flex
Units. These temperatures are relayed to the Chassis Load Controller (FLC) Circuit Theory of Operation
Control Unit (CCU) which controls the relief valve (S.N. 590068— ). (Group 9015B-15.)
solenoid.
This controlled fan speed is more economical and fuel

efficient.
TX,9025,ME406 –19–07NOV03–1/1

092005
PN=697
Theory Of Operation
Steering System Components
NOTE: See Hydraulic System Component Location. control valve and back to the hydraulic pump. This
(Group 9025-15.) signal controls pump flow. The steering load sense
signal in the load control valve, provides priority to
The steering hydraulic system consists of a steering by utilizing compensator valves in each loader
variable-displacement pump supplying a closed center function. The compensator will restrict flow to any
steering and loader system. The components of the loader function that has a work load pressure less than
steering system are: the steering work load pressure.
• Piston Pump An optional secondary steering system is used to

• Steering valve with Load Sense provide temporary steering flow in the event of a flow
• Priority valve loss in the steering hydraulic system. The secondary
• Steering cylinders steering gear type pump, is driven by an electric
motor. The secondary steering inlet manifold is a valve
The hydraulic pump draws oil from the reservoir. Outlet connected to the steering valve inlet. The manifold
flow from the pump flows to the steering valve. When contains two check valves which isolate secondary
the machine is steered, the steering valve routes flow steering flow and a pressure switch which controls
to the steering cylinders to articulate the machine. operation of the secondary steering motor.
Steering load sense is directed through the load
TX,9025,ME318 –19–28AUG96–1/1
9025
05
14

092005
PN=698
Theory Of Operation
Steering Valve Operation
A NEUTRAL
B STEERING
CYLINDERS
C ANTI-CAVITATION VALVES
LOAD SENSE PORT TO LOADER
D CONTROL
VALVE
E GEROTOR
K SYSTEM PRESSURE OIL

SPOOL I G RETURN L WORK PRESSURE OIL
–19–05AUG98
J STEERING SLEEVE H
G M TRAPPED OIL
SHAFT F
RETURN N RETURN PRESSURE OIL
FROM HYDRAULIC
PUMP
T106786
T106786
O STEERING VALVE OPERATION
A—Neutral E—Gerotor I—Spool M—Trapped Oil

B—Steering Cylinders F—From Hydraulic Pump J—Steering Shaft N—Return Pressure Oil
C—Anti-Cavitation Valves G—Return K—System Pressure Oil O—Steering Valve Operation
D—Load Sense Port To Loader H—Sleeve L—Work Pressure Oil
Control Valve
9025
05
The steering valve (O) consists of a spool (I) inside a A bypass orifice is machined into the spool and sleeve 15
sleeve (H) within a housing. When steering wheel is assembly. It is a variable orifice that introduces a small
not moving, the valve is in the neutral (A) position. In leak into the pressure side of the steering valve. Its
neutral, the spool and sleeve are aligned so that oil purpose is to dampen the initial pressure surge when
flow through the valve is blocked. The steering the steering wheel is partially turned. When the
cylinders (B) are held stationary by trapped oil in the steering wheel is fully turned, the leak is closed off.
left and right workports.
Return oil flows back in through the left workport
When the steering valve is turned to the right, the through the spool and sleeve assembly to return. The
spool rotates relative to the sleeve, and opens load-sensing orifice is located between the sleeve and
passages which allow pump flow through the spool the gerotor. This orifice feeds the load-sensing
and sleeve assembly. Oil flows to the gerotor (E) pressure to loader control valve.
causing the gerotor gear to rotate. Oil flow from the
gerotor flows back into the valve where it is directed
out the right workport to the respective ends of the
steering cylinders.
Continued on next page TX,05,SS3714 –19–28AUG96–1/2

092005
PN=699
Theory Of Operation
When the rotation of the steering wheel stops, the A variable orifice bypasses oil around the gerotor.
gerotor gear continues to move, turning the sleeve, Turning the steering wheel slowly takes approximately
until the sleeve stops the flow to the gerotor. At this seven turns (variable orifice small) stop-to-stop versus
point, the valve is back in the neutral position and will three turns (variable orifice large) when turning the
remain there until the steering wheel is moved again. steering wheel quickly.
The valve has a variable steering rate which is Four anti-cavitation balls are located inside the spool.
proportional to the speed the steering wheel is rotated. (Not shown.)
TX,05,SS3714 –19–28AUG96–2/2
9025
05
16

092005
PN=700
Theory Of Operation
Secondary Steering Inlet Manifold Operation
E
G
B
SWITCH LEVER
H
E J LS-PORT
I I SECONDARY
PISTON
MAGNET CHECK VALVE
D
G J
SPRING
C
ORIFICE
B 9025
05
A F 17
INLET
PRIMARY
CHECK VALVE K OUTLET F K L STEERING PRESSURE
–19–07NOV97
M LS PRESSURE
O INLET MANIFOLD N RETURN PRESSURE T6567OL
T6567OL
A—Inlet E—Switch I—LS-Port M—LS-Pressure

B—Orifice F—Outlet J—Secondary Check Valve N—Return Pressure
C—Spring G—Magnet K—Primary Check Valve O—Inlet Manifold
D—Piston H—Lever L—Steering Pressure
The secondary steering inlet manifold isolates the main

steering system and provides a signal to the controller
to warn of low steering pressure.

092005
PN=701
Theory Of Operation
During normal steering operation, pump flow enters drops, causing pressure through the orifice to drop,
from the hydraulic pump through the inlet (A), unseats causing the spring, plus load-sensing pressure through
the primary check valve (K), and flows to the steering the LS-port (I), to move the piston up. The magnet (G)
valve through the outlet (F). Inlet pressure is sensed pulls lever (H), which opens the switch.
on top of the piston (D) through the orifice (B) to move
the piston down against the spring (C) and When the switch opens, the Chassis Control Unit
load-sensing pressure. With the main hydraulic pump (CCU) (S.N. —590067) or Flex Load Controller (FLC)
supplying flow, the steering inlet pressure is higher (S.N. 590068— ) energizes the secondary steering
than load-sensing pressure. This pressure difference relay. The relay energizes the secondary steering
keeps the switch (E) in the closed position. motor which drives the pump. Pump flow unseats the
secondary check valve (J) providing temporary
If main pump flow is lost, the primary check valve steering flow.
seats. The pilot pressure in the loader control valve
TX,05,SS3716 –19–28AUG96–2/2
Secondary Steering System Operation
NOTE: See Hydraulic System Component Location. If pump flow is lost, the decrease in system pressure
(Group 9025-15.) opens a pressure switch in the inlet manifold. The
opened pressure switch signals the Chassis Control
The secondary steering system provides temporary Unit (CCU) (S.N. —590067) or Flex Load Controller
flow in the event of a loss of main pump flow. (FLC) (S.N. 590068— ) to energize the relay. The
relay energizes the electric pump which provides flow
The key switch provides a power source to the through the inlet manifold. The dash mounted indicator
controller. The controller contains the electronic is also energized, indicating the system is operating.
circuitry to control the operation of the secondary Two check valves in the inlet manifold isolate the
9025
05 steering system. When the machine is started, the secondary steering pump flow from the rest of the
18 start switch button is depressed, sending a signal to system.
the controller that the machine is in use.
TX,9025,ME321 –19–28AUG96–1/1

092005
PN=702
Theory Of Operation
Pressure Reducing Valve—Boom Raise Operation (S.N. —590067)
D E
C PUMP REGULATED
INLET PRESSURE PRESS
B
PILOT
CHECK
VALVE F PILOT
ENABLE
G SOLENOID
A PRESSURE
REDUCING
VALVE
P ORIFICE
H DIFF LOCK
BRAKE
ACCUMULATOR O
N
CHECK I DIFF LOCK
VALVE SOLENOID
J
SUMP
M K
G F BOOM CHECK
VALVE
D 9025
E 05
B P 19
C A .096
H
L BOOM DOWN
SOLENOID
L
K Q PRESSURE OIL
I
R PILOT OIL
–19–13APR99
O N J S RETURN OIL
M
T121029
T121029 T PRESSURE REDUCING VALVE - BOOM RAISE
A—Pressure Reducing Valve G—Pilot Enable Solenoid L—Boom Down Solenoid Q—Pressure Oil
B—Check Valve H—Differential Lock M—Boom R—Pilot Oil
C—Inlet I—Differential Lock Solenoid N—Check Valve S—Return Oil
D—Pump Pressure J—Sump O—Brake Accumulator T—Pressure Reducing Valve—
E—Regulated Pressure K—Check Valve P—Orifice Boom Raise
F—Pilot

092005
PN=703
Theory Of Operation
The pressure reducing manifold contains several and flows through the spool. The oil flows to the pilot
components which are part of the hydraulic and the controllers through passage (F).
pilot control systems. These components are:
When the pilot enable solenoid valve is de-energized,
• Combination source valve/pressure reducing valve pilot circuit flow is blocked and passage (F) is open to
• Pilot enable solenoid valve return.
• Differential lock solenoid valve (If equipped)
• Boom down solenoid valve When the differential lock solenoid valve is energized
the spool shifts up in the sleeve. Pilot oil enters the
Oil flow from the hydraulic pump is supplied to the sleeve and flows through the spool to passage (H).
pressure reducing manifold from two sources. The first Passage (H) routes flow to the differential clutch(es) to
source is directly from the pump and enters through engage the differential lock. When the differential lock
inlet (C). The second source is supplied through the solenoid valve is de-energized, differential lock flow is
brake accumulator, across the boom down solenoid blocked and passage (H) is open to return.
valve and enters through port (O). Oil from the brake
accumulator is available whenever the boom down If a pressure spike is encountered in either the
solenoid valve is activated. The boom down solenoid is differential lock or the pilot circuit, the pressure source
electrically in parallel with the pilot enable solenoid. valve/pressure reducing valve will shift down against
Whenever the pilot enable solenoid is activated the the spring, blocking pump flow. With the spool shifted
boom down solenoid is also energized. down far enough against the spring, the excess
pressure in the pilot circuit will be bled to return.
The combination source valve/pressure reducing valve
has two functions. The first function is to select the The differential lock return check valve (K) prevents oil
source of oil supply with the highest pressure. Upon from the reservoir return passage from draining back
start-up, the spring has the source valve held up and into the differentials which are at a lower point on the
oil is available from both the hydraulic pump and the machine.
brake accumulator. As pressure builds between the
source valve and the orifice (P), the valve will move There are three operating conditions: neutral, high
down and oil will be supplied from the hydraulic pump pressure function and low pressure function.
only. In the event of a loss of flow from the hydraulic
pump, check valve (B) will seat, the source valve will In neutral, the pressure reducing valve is supplied low
move up and the brake accumulator will provide flow standby pressure both from the pump and from the
9025 for the pilot circuit. brake accumulator. Since standby pressure is above
05 the setting of the pressure reducing valve, operation is
20
The second function of the combination source normal.
valve/pressure reducing valve is to regulate pump flow
to maintain pilot circuit pressure. Pilot circuit pressure When a high pressure function is being operated,
is available through orifice (P) to the inlet of the example boom raise, high pressure will be supplied
differential lock solenoid valve and the pilot controllers from the pump and brake accumulator. The pressure
through the pilot enable solenoid valve. reducing valve will reduce this pressure to its specified
setting and operation is normal.
When the pilot enable solenoid valve is energized the
spool shifts up in the sleeve. Pilot oil enters the sleeve
CED,TX17994,360 –19–27JUL00–2/2

092005
PN=704
Theory Of Operation
Pressure Reducing Valve—Boom Down—Engine Running Operation (S.N. —590067)
D E
C PUMP REGULATED
INLET PRESSURE PRESSURE
B
PILOT
CHECK
VALVE F PILOT
ENABLE
G SOLENOID
A PRESSURE
REDUCING
VALVE
P ORIFICE
H DIFF LOCK
BRAKE
ACCUMULATOR O
N
CHECK I DIFF LOCK
VALVE SOLENOID
J
SUMP
M K
G F
BOOM CHECK
VALVE
D 9025
E
B P 05
21
C A .096
H
L BOOM DOWN Q PRESSURE OIL
L SOLENOID R LOW PRESSURE OIL
K I
S PILOT OIL
–19–06APR99
O N J T RETURN OIL
M
T121031
T121031 U PRESSURE REDUCING VALVE - BOOM DOWN - ENGINE RUNNING
A—Pressure Reducing Valve G—Pilot Enable Solenoid M—Boom S—Pilot Oil

B—Check Valve H—Differential Lock N—Check Valve T—Return Oil
C—Inlet I—Differential Lock Solenoid O—Brake Accumulator U—Pressure Reducing Valve—
D—Pump Pressure J—Sump P—Orifice Boom Down—Engine
E—Regulated Pressure K—Check Valve Q—Pressure Oil Running
F—Pilot L—Boom Down Solenoid R—Low Pressure Oil

092005
PN=705
Theory Of Operation
During a low pressure condition, (example: boom momentarily supply the pressure reducing valve and
down) the pump outlet pressure could drop to a very thereby maintain normal pressure to the pilot and
low level. In this condition check valves (B) and (N) will differential lock circuits.
close. This allows the brake accumulator to
TX,9025,ME324 –19–10AUG96–2/2
9025
05
22

092005
PN=706
Theory Of Operation
Pressure Reducing Valve—Boom Down—Engine OFF Operation (S.N. —590067)
D E
C PUMP REGULATED
INLET PRESSURE PRESS
B
PILOT
CHECK
VALVE F PILOT
ENABLE
G SOLENOID
A PRESSURE
REDUCING
VALVE
P ORIFICE
H DIFF LOCK
BRAKE
ACCUMULATOR O
N
CHECK I DIFF LOCK
VALVE SOLENOID
J
“SUMP”
M K
G F “BOOM”
CHECK
VALVE
D 9025
E
B P 05
23
C A .096
H Q PRESSURE OIL
L BOOM DOWN
SOLENOID R PILOT OIL
L
K I S RETURN OIL
–19–06APR99
O N J
M
T121030
T121030 T PRESSURE REDUCING VALVE - BOOM DOWN - ENGINE OFF
A—Pressure Reducing Valve G—Pilot Enable Solenoid L—Boom Down Solenoid Q—Pressure Oil
B—Check Valve H—Differential Lock M—Boom R—Pilot Oil
C—Inlet I—Differential Lock Solenoid N—Check Valve S—Return Oil
D—Pump Pressure J—Sump O—Brake Accumulator T—Pressure Reducing Valve—
E—Regulated Pressure K—Check Valve P—Orifice Boom Down—Engine OFF
F—Pilot
Continued on next page TX,9025,ME325 –19–27JUL00–1/2

092005
PN=707
Theory Of Operation
The secondary boom lower circuit is a solenoid are energized by activating the pilot enable boom
operated circuit which allows the operator to lower the down switch to the momentary position. This connects
boom with the engine off. With the engine off, the unswitched power to both solenoids.
secondary boom lower circuit has the possibility of
receiving oil flow from two sources. When the boom down solenoid is energized, the spool
will shift allowing trapped oil to flow through the sleeve
With the boom off the ground, trapped oil in the head to the pressure reducing valve. The pressure reducing
end of the boom cylinders is one source of oil. The valve meters the flow to the pilot controllers to
second source of oil is from one of the brake maintain pilot pressure at the controllers so the control
accumulator. valve spool can be moved to lower the boom or dump
the bucket.
The boom down solenoid and the pilot enable solenoid
are both activated at the same time. Both solenoids
TX,9025,ME325 –19–27JUL00–2/2
9025
05
24

092005
PN=708
Theory Of Operation
Pressure Reducing Valve Operation (S.N.

590068— )
The pressure reducing valve (PRV) manifold contains:
• Pressure reducing valve (PRV)

• Pilot enable solenoid
• Differential lock solenoid
• Boom down accumulator solenoid
• Boom down accumulator
For hydraulic system operation, see Hydraulic System

Schematics. (Group 9025-15.)
The pressure reducing valve manifold receives system

pressure directly from pump outlet. System pressure oil
flows through a check valve to the boom down
accumulator solenoid and adjustable pressure reducing
valve. Oil then flows to the pilot enable and differential
lock solenoids through internal manifold filters. The pilot
enable solenoid allows oil to flow to the pilot control valve
and the differential lock solenoid allows oil to flow to the
differential lock. The PRV regulates pressure to the pilot
controls and differential lock by bleeding excess pressure
to reservoir. Pilot control pressure, differential lock
pressure, and accumulator charge should be within
specification with engine running.
Specification
Pilot Control—Pressure .................................................. 4100—4400 kPa
41—44 bar
600—650 psi
9025
With pilot enable solenoid de-energized, a bias spring 05
holds pilot enable spool up venting oil in pilot controls to 25
reservoir. With pilot enable solenoid energized, spool
shifts down connecting regulated pilot pressure to pilot
controls.
With differential lock solenoid de-energized, a bias spring

holds the differential lock spool down venting oil in
differential lock through a check valve to reservoir. With
differential lock solenoid energized, spool shifts up
connecting regulated pressure to differential lock. See
Hydraulic System Schematics. (Group 9025-15.)
Boom or Bucket Down Operation
Continued on next page DW09104,00000AD –19–14OCT03–1/2

092005
PN=709
Theory Of Operation
With engine on and pilot controls enabled, the boom down

accumulator solenoid activates shifting the spool down to
allow regulated pressure oil to flow to and from the boom
down accumulator. Oil can flow to accumulator in either
spool position. With engine off, accumulator can only
discharge when key is in on position and pilot enable
button is depressed. With pilot enable switch activated,
operator can cycle pilot control lever allowing accumulator
to discharge and lower boom or bucket.
DW09104,00000AD –19–14OCT03–2/2
Service Brake Hydraulic System
NOTE: See Hydraulic System Schematics for brake Circuit Theory of Operation (S.N. —590067) (Group
system operation. (Group 9025-15.) 9015A-15) or see Flex Load Controller (FLC) Circuit
Theory of Operation (S.N. 590068— ). (Group
Loader service brakes are operated by a load sensing 9015B-15.) The shuttle valve is used to isolate the
pressure compensated, closed center hydraulic accumulators. The brake valve is a closed center
system. Flow is supplied by a variable displacement, design and can be operated by pressing on either the
axial piston hydraulic pump. Pressure to the brake left or right pedal. The single brake valve operates
system varies from low standby to the maximum both the front and rear brakes. Brake outlet pressure
pressure where the load sense relief valve in the flows through orifice check valves to assure that if
loader control valve limits extreme pressure. either brake line is damaged, brakes on the remaining
axle will still function. Brakes are self bleeding during
The hydraulic pump supplies oil flow to the operation.
accumulators. The accumulators have a gas
pre-charge and inlet check valves to maintain a A brake light pressure switch is used to sense brake
pressurized volume of oil for reserve brake outlet pressure for activating the brake lights.
applications.
9025
Clutch cut-off is controlled through the Transmission
05
26 Oil from the accumulators flows through a shuttle valve Control Unit (TCU) by a potentiometer signal activated
to the single brake valve. A pressure switch senses by the brake pedal linkage. See Transmission Control
pressure at the brake valve inlet. Low pressure triggers Unit Circuit Theory of Operation (S.N. —590067)
a warning signal to the Chassis Control Unit (CCU) (Group 9015A-15) or see Transmission Control Unit
(S.N. —590067) or Flex Load Controller (FLC) (S.N. (TCU) Circuit Theory of Operation (S.N. 590068— ).
590068— ) and monitor. See Chassis Control Unit (Group 9015B-15.)
DW09104,000009D –19–13OCT03–1/1

092005
PN=710
Theory Of Operation
Service Brake Accumulator
–19–19NOV03
T196150
A—Inlet Check Valve D—Outlet G—Precharge Pressure H—Brake Accumulator
C—Piston E—Brake Circuit Pressure
NOTE: Brake accumulator is not repairable and is If pump flow stops, the inlet check valve will close 9025
serviced as a complete unit. against inlet fitting which is machined to provide a 05
27
check valve seat, keeping the accumulator charged.
The accumulator is used to store pressurized oil for The accumulator will remain pressurized until the
reserve brake application. The top of the accumulator brakes are applied. The volume of the accumulator will
is charged with dry nitrogen gas. When the hydraulic allow several brake applications in the event of a loss
system pressure exceeds the charge pressure, oil of brake pump flow.
flows through the inlet (E) and inlet check valve (A).
The piston (C) moves upward until gas pressure is
equal to hydraulic circuit pressure.
TX,9025,ME327 –19–06NOV03–1/1

092005
PN=711
Theory Of Operation
Service Brake Valve
B
C
SERVICE B INLET
BRAKE A
C RETURN
PRESSURE
SWITCH
D
ONE-WAY N
ORIFICES
M
BRAKE LIGHT
PRESSURE SWITCH D WORKPORTS
E BRAKE SHUTTLE
VALVE
FROM BRAKE L F FROM BRAKE/PRV

ACCUMULATOR ACCUMULATOR
G SPOOL
9025
05
28
H PLUNGER
SNAP K B
RING C
D
I TO FRONT
TO REAR J
BRAKES BRAKES
–19–09JUL98
O INLET PRESSURE
P METERED PRESSURE
T116212
Q RETURN PRESSURE
T116212 R BRAKE VALVE OPERATION
Continued on next page TX,9025,ME417 –19–10JUL00–1/2

092005
PN=712
Theory Of Operation
A—Service Brake Pressure F—From Brake/PRV J—To Rear Brakes N—One-Way Orifices
Switch Accumulator K—Snap Ring O—Inlet Pressure
B—Inlet G—Spool L—From Brake Accumulator P—Metered Pressure
C—Return H—Plunger M—Brake Light Pressure Q—Return Pressure
D—Workports I—To Front Brakes Switch R—Brake Valve Operation
E—Brake Shuttle Valve
The brake valve is a closed center, manually operated metering notch on the spool starts to open, allowing
spool-type valve. One valve is used to actuate both the brake pressure oil from the inlet (B) to the workports
front and rear brakes. Orifice check valves are used in (D). The brakes in the front and rear axles begin to
the brake lines so that if either brake line is damaged, engage.
the remaining axle brake will still function.
When the brakes are fully engaged, the spool is
Brake pressure oil from the accumulators enters the moved to the far left position against the spring. Full
inlet (B). When the valve is in neutral, oil in the inlet flow at a regulated pressure is available to the
workports is routed to return through passage (C). workports to engage the brakes.
When the brakes are partially engaged, the brake
pedal pushes the plunger (H) against a spring which The brake valve regulates brake application pressure
contacts the guide. The spool has a metering notch based on brake pedal travel. When the inlet is opened
which begins to trap the workport oil from the return to pressurize the workports, the orifice (N) allows
passage. workport pressure on the left end of the spool. The
workport pressure plus spring force on the left end of
As the brake pedal is further depressed, the plunger the spool balance against the compressed spring force
(H) compresses the spring against the guide which on the right end of the spool. This meters the inlet
moves the spool (G) further to the left. As the spool, pressure oil to prevent aggressive braking or brake
moves to the left, the return passage (C) is blocked. A lock-up.
9025
05
TX,9025,ME417 –19–10JUL00–2/2
29

092005
PN=713
Theory Of Operation
Pin and Axle Disconnect Operation

1
See Hydraulic System Component Location (Group
9025-15) for entire hydraulic system operation.
Pin (5) and axle disconnect (2) solenoids are housed in 2

pin/axle disconnect valve (1). They share a common inlet 7 6
from pump outlet pressure (7) where pressure reducing
valve (6) reduces system pressure to specification. If 3
machine is equipped with only one of these options, the
manifold valve with both solenoids will be used. However
only one of the solenoids will have electrical and hydraulic
connections. 8
5
–UN–24OCT03
Specification
Pin/Axle Disconnect—Regulated 4
Pressure ...................................................................................... 7584 kPa
76 bar
1100 psi
T195522
With axle engaged, solenoid (2) is de-energized and
pressure oil is blocked from axle disconnect. With 1—Pin/Axle Disconnect Manifold Valve
solenoid (2) energized, axle disconnect spool shifts 2—Axle Disconnect Solenoid
allowing pressure oil to disengage the front axle. See Axle 3—Axle Disconnect
Disconnect Operation. (Group 9020-05.) 4—Pin Disconnect Cylinder
5—Pin Disconnect Solenoid
6—Pin/Axle Disconnect Pressure Reducing Valve
During pin disconnect operation, solenoid (5) energizes 7—Pump Outlet Pressure
allowing pressure oil to shift the pin disconnect spool and 8—Return Line to Reservoir
flow to end of cylinder to retract pins. With solenoid (5)
de-energized, pressure oil flows to center of cylinder
holding pins in the extended position. Cylinder rod ends
are joined by a common tube to the reservoir.
9025
05
30
DW09104,000008A –19–13OCT03–1/1
Pilot Control Lever Operation (S.N. —590067)
Boom Float

092005
PN=714
Theory Of Operation
9025
05
31

092005
PN=715
Theory Of Operation
CONTROL LEVER A
PULL PLATE N
B PUSH BAR
ELECTRIC COIL M
C PLUNGER
D SPRING GUIDE
MECHANIC
FEEL POSITION L E METERING SPRING
F RETURN SPRING
9025 G SPOOL ASSEMBLY

05
32
A T
P C
O PILOT PRESSURE OIL C B
P PRESSURE FREE OIL K J I

(RETURN) P
"A" PORT "P" PORT "C" PORT
–19–14JAN98
D A
PILOT CONTROLLER - BOOM FLOAT

T101974
T101974 Q
H END VIEW

092005
PN=716
Theory Of Operation
A—Control Lever F—Return Spring K—“A” Port O—Pilot Pressure Oil

B—Push Bar G—Spool Assembly L—Mechanical Feel Position P—Pressure Free Oil (Return)
C—Plunger H—End View M—Electric Coil Q—Pilot Controller—Boom
D—Spring Guide I—“C” Port N—Pull Plate Float
E—Metering Spring J—“P” Port
The pilot controller is an assembly of four, control lever in the float position but it can be manually
two-position, two-way, lever-operated valves. The disengaged by pulling back on the control lever. An
standard controller has a single lever which moves optional return-to-carry feature is also available. With
fore and aft as well as side to side. A dual lever return-to-carry activated and the pilot controller in the
controller is available as an option where each lever float position, the boom will float down until it reaches
moves fore and aft. a preset height. The magnetic detent will release when
the boom reaches the preset position and the
In neutral, the return spring (F) holds the spool return-to-carry switch on the boom opens.
assembly (G) closed, blocking flow from the P-port (J)
to the C port (I). During operation, pilot pressure oil (O) The boom lower function of the pilot controller also
from the pressure reducing valve enters the pilot contains a mechanical feel position (L). The operator
controller housing at the P-port. With the control lever will feel a slight resistance in the pilot controller when
(A) pushed forward, the push bar (B) pushes the going from boom lower to float.
plunger (C) down which contacts the spring guide (D).
The spring guide compresses both the return spring The boom raise function also uses an electromagnetic
(F) and the metering spring (E) which moves the spool detent. The operation of this detent is identical to the
assembly (G) down, into a metering position allowing boom float detent.
oil to flow out the A-port (K). With the spool assembly
moved down all the way, full pilot pressure will be The end view (H) shows the workport location of the
available to shift the boom control valve spool. single-lever four-function pilot controller. When the
Approximately 500 psi is needed to shift the boom valves are in neutral, the flow is blocked from the
spool to the float position. P-port to the workports. The workports are opened to
return through the spring area in the pilot controller
The boom float function uses an electromagnetic which is connected to the T-port on the bottom of the
detent. When the control lever is moved forward to the valve.
float position, the pull plate (N) comes in contact with
the electric coil (M). The pull plate is held downward Bucket Rollback
by the electromagnet with enough force to hold the 9025
05
33

092005
PN=717
Theory Of Operation
A CONTROL LEVER
PULL PLATE L
PUSH BAR K
ELECTRIC COIL J B PLUNGER
SPRING GUIDE I
C METERING SPRING
RETURN SPRING H
D SPOOL ASSEMBLY
9025
05
34
D P B
M PILOT PRESSURE OIL
N PRESSURE FREE OIL

G F E (RETURN)
"D" PORT "P" PORT "B" PORT
–19–14JAN98
O PILOT CONTROLLER - BUCKET ROLLBACK

T101922
T101922
A—Control Lever E—“B” Port I—Spring Guide M—Pilot Pressure Oil

B—Plunger F—“P” Port J—Electric Coil N—Pressure Free Oil (Return)
C—Metering Spring G—“D” Port K—Push Bar O—Pilot Controller—Bucket
D—Spool Assembly H—Return Spring L—Pull Plate Rollback

092005
PN=718
Theory Of Operation
The pilot controller is shown in the bucket rollback The return-to-dig function is controlled by a bucket
position during return-to-dig operation. mounted linkage which controls a switch. When the
bucket is dumped, the switch closes and the
With the control lever (A) partially held in the return-to-dig detent is energized. When the control
return-to-dig position, the push bar (K) pushes the lever is moved to the full left position, the pull plate (L)
plunger (B) down which contacts the spring guide (I). comes in contact with the electric coil (J). The pull
The spring guide compresses both the return spring plate is held downward by the electromagnet with
(H) and the metering spring (C) which moves the spool enough force to hold the control lever in the bucket
assembly (D) down, into a metering position, allowing rollback position. The detent will release when the
oil to flow out the "D" port (G). bucket reaches the pre-set position and the switch on
the bucket linkage opens. The detent can also be
The pressure in the pilot controller workport controls manually released by moving the control lever to the
the amount of stroke of the function spool in the loader right.
control valve. As the control lever is moved further
from neutral, the compression of the metering spring The optional two-lever controller is designed and
(C) is greater. The controller workport pressure acts on operated the same as the single lever controller.
the bottom of the spool assembly (D) which pushes up
on the metering spring to regulate the pressure
delivered to the bucket control valve spool.
TX,9025,ME330 –19–10AUG96–5/5
9025
05
35

092005
PN=719
Theory Of Operation
Pilot Control Lever Operation (S.N. 590068— )
10 4
11
9025 5
05
36 6
7 –UN–12NOV03
9 8
T195551
T195551
Continued on next page DW09104,00000B2 –19–11NOV03–1/2

092005
PN=720
Theory Of Operation
1—Wobble Plate 4—Extra Centering Spring 7—Spool Assembly 10—Plunger Assembly

2—Push Rod 5—Metering Spring 8—Workport A 11—Spring Guide
3—Pull Plate 6—Return Spring 9—Workport C
Single lever pilot control levers moves fore and aft as With the control lever pushed activated in either
well as side to side and consists of four, two position, direction, the push rod (2) pushes plunger (10) down
two way, lever operated valves. Fingertip pilot control contacting spring guide (11). Spring guide (11)
levers have a pair of levers that move fore and aft compresses both return spring (6) and metering spring
consisting of two, two way, two position, lever operated (5) moving spool assembly (7) down into a metering
valves. Both pilot controllers operate the same way. position and allowing oil to flow out the workport. With
the spool assembly moved to maximum travel, full pilot
In neutral, the return spring (6) and extra centering pressure will be available to shift the control valve
spring (4) hold spool assembly (7) closed blocking flow spool.
from the pressure port to connect to work ports and
allowing oil to return to reservoir. During operation, Boom float and raise functions use an electromagnetic
pilot pressure oil from the pressure reducing valve detent.
enters the pilot controller housing at the pressure port.
DW09104,00000B2 –19–11NOV03–2/2
9025
05
37

092005
PN=721
Theory Of Operation
Pilot Orifice Check Valve For Control Valve Sections
A ORIFICE CHECK PLATE
TOP VIEW
C RESTRICTED
RETURN OIL
CONTROL B D RETURN OIL
VALVE
END CAP
–19–28AUG96
T102095
T102095 E PILOT OIL RETURN RESTRICTED
A—Orifice Check Plate C—Restricted Return Oil D—Return Oil E—Pilot Oil Return Restricted
B—Control Valve End Cap
9025 Orifice check plate is installed in control valve pilot cap the pilot controller lever is centering itself. It also stops
05 of bucket and auxiliary control valve sections. Orifice unwanted correction in other direction as the lever
38
(A) dampens the control valve spool movement to stop kicks out of bucket return-to-dig.
unwanted bucket or auxiliary function movement when
TX,05,SS3728 –19–13OCT03–1/1

092005
PN=722
Theory Of Operation
9025
05
39

092005
PN=723
Theory Of Operation
Loader Control Valve
9025
05
40
–19–14JUN00
T131602
Continued on next page TX,9025,ME333 –19–16OCT03–1/2

092005
PN=724
Theory Of Operation
A—“B” Auxiliary Workport H—Load Sense Relief Valve— O—Anti-Cavitation V—Inlet from Pump
B—Circuit Relief Maximum System Pressure P—Boom Lower Pilot W—Load Sense from Steering
C—Auxiliary Pilot I—Load Sense to Pump Q—Bucket Dump Pilot X—Stroke Adjuster
D—Bucket Rollback Pilot J—Shuttle Check Valves R—Auxiliary Pilot Y—Pressure Switch (Ride
E—Boom Raise Pilot K—Return Port—With Orifice S—Circuit Relief Control)
F—Bucket Rollback Relief L—Return from Ride Control T—“A” Auxiliary Workport Z—Loader Control Valve
Valve M—Boom Lower Workport U—Loader Relief Valve
G—Boom Raise Valve N—Bucket Dump Workport (Clipper)
TX,9025,ME333 –19–16OCT03–2/2
9025
05
41

092005
PN=725
Theory Of Operation
Boom Section—Boom Down And Steering
C3
SHUTTLE D COMPENSATOR E BOOM
CHECK C ASSEMBLY RAISE
BOOM LOWER B WORKPORT
WORKPORT
ANTI-CAVITATION F STEERING
CHECK A LOAD
SENSE
BOOM G
M RAISE
PILOT
BOOM
LOWER H BLEED TO
K
PILOT J C1 CHECK
TO OUTLET, OUTLET SECTION
AUXILIARY
AND BUCKET I STEERING
SECTIONS LOAD SENSE TO
ISOLATION VALVE
9025
05
42
D
J
N HIGH PRESSURE
O LOAD SENSE (STEERING)
P LOAD SENSE (BOOM)
Q PILOT PRESSURE
–19–24OCT03
A R RETURN PRESSURE
T195613
T195613 S BOOM SECTION - BOOM DOWN AND STEERING

092005
PN=726
Theory Of Operation
A—Anti-Cavitation Check G—Boom Raise Pilot K—To Outlet Auxiliary and P—Load Sense (Boom)
B—Boom Lower Workport H—Bleed to Outlet Section Bucket Sections Q—Pilot Pressure
C—C3 Shuttle Check I—Steering Load Sense to M—Boom Lower Pilot R—Return Pressure
D—Compensator Assembly Isolation Valve N—High Pressure S—Boom Section—Boom
E—Boom Raise Workport J—C1 Check O—Load Sense (Steering) Down and Steering
F—Steering Load Sense
NOTE: An external orifice check valve is located in a the compensator. Steering load sense (F) comes from
fitting between the pilot port and hose. the steering valve through the inlet section to the
center area of the compensator. It is then directed out
The boom lower workport has an anti-cavitation check, to the isolation valve in the outlet section. This
the boom raise is plugged. There are no circuit relief pressure comes back from the isolation valve to C3
valves. and the spring area of the compensator.
Two load sense pressures are generated. There are Since the steering load sense pressure is much
several connection to the load sense circuit. There is a greater than the boom workport load sense pressure,
compensator assembly that is controlled by the load the compensator restricts oil flow to boom down. This
sense circuit. provides priority to steering.
During a boom down and steering operation the The bleed to outlet section (H) provides a bleed of the
following will occur. Pilot oil shifts the spool to the “bridge” passage when the spool is in neutral. This
right. Oil flow from the pump is directed to the spool insures that there is no trapped load sense pressure in
center. Metered load sense flows past C1 check (J) to the “bridge” passage in neutral. This passage is
the outlet (K) section. It also exerts an upward force on blocked when the spool is moved in either direction.
9025
05
TX,9025,ME334 –19–07OCT03–2/2
43

092005
PN=727
Theory Of Operation
Boom Section—Boom Raise And Bucket Dump
C3
SHUTTLE D COMPENSATOR E BOOM
CHECK C ASSEMBLY RAISE
BOOM LOWER B WORKPORT
WORKPORT
ANTI-CAVITATION F BUCKET LOAD

CHECK A SENSE
BOOM G
RAISE
M
PILOT
BOOM H
LOWER BLEED TO
PILOT K J C1 CHECK
TO OUTLET, OUTLET SECTION
AUXILIARY
AND BUCKET I BOOM LOAD
SECTIONS SENSE TO
ISOLATION VALVE
9025
05
44
D
J
N HIGH PRESSURE
O LOAD SENSE (BOOM)
P LOAD SENSE (BUCKET)
Q PILOT PRESSURE
R RETURN PRESSURE
A
–19–24OCT03
T195614
T195614
S BOOM SECTION - BOOM RAISE AND BUCKET DUMP

092005
PN=728
Theory Of Operation
A—Anti-Cavitation Check G—Boom Raise Pilot K—To Outlet Auxiliary and P—Load Sense (Bucket)
B—Boom Lower Workport H—Bleed to Outlet Section Bucket Sections Q—Pilot Pressure
C—C3 Shuttle Check I—Boom Load Sense to M—Boom Lower Pilot R—Return Pressure
D—Compensator Assembly Isolation Valve N—High Pressure S—Boom Section—Boom
E—Boom Raise Workport J—C1 Check O—Load Sense (Boom) Raise and Bucket Dump
F—Bucket Load Sense
NOTE: An external orifice check valve is located in a hydraulic pump. Regulated load sense flows from the
fitting between the pilot port and hose. bridge passage to the compensator center, seats the
ball check to up position and flows out to the isolation
During boom raise and bucket dump oil flow to these valve in the outlet section. The isolation valve directs
two functions will be equal even though there is a high load sense pressure back to C3 and to the spring
large difference in workport pressures. This is area of the compensator. This identical high load
accomplished by the load sense pressure control of sense pressure is also directed to the bucket
the boom and bucket compensators. compensator spring area. With both compensators
having the same spring pressure the same hydraulic
During boom raise the workport and load sense force will be required to lift or open both valves. Thus
pressures will be high. Metered load sense flows past the flow to both functions will be the same. Even
C1 check (J) to the outlet section and back to the though the bucket workport pressure is quite low.
TX,9025,ME335 –19–07OCT03–2/2
9025
05
45

092005
PN=729
Theory Of Operation
Bucket Section—Boom Raise and Bucket Dump
C3 D COMPENSATOR E BUCKET
SHUTTLE ASSEMBLY ROLLBACK
CHECK C WORKPORT
BUCKET DUMP B
WORKPORT
F STEERING OR
AUXILIARY LOAD
CIRCUIT RELIEF A SENSE
AND
ANTI-CAVITATION
G BUCKET
M L ORIFICE ROLLBACK
CHECK PILOT
BUCKET
DUMP PLATE H BLEED TO
PILOT K OUTLET SECTION
J C1 CHECK
TO OUTLET,
AUXILIARY I LOAD SENSE TO
AND BOOM BOOM SECTION
SECTIONS
9025 C
05
46
D
J
N HIGH PRESSURE
O LOAD SENSE (BOOM)
A A
P LOAD SENSE (BUCKET)
Q PILOT PRESSURE
R RETURN PRESSURE
–19–19SEP97
S
T106960
T106960 BUCKET SECTION - BOOM RAISE AND BUCKET DUMP
Continued on next page TX,05,SS3708 –19–07OCT03–1/2

092005
PN=730
Theory Of Operation
A—Circuit Relief and F—Steering or Auxiliary Load J—C1 Check P—Load Sense (Bucket)
Anti-Cavitation Sense K—To Outlet Auxiliary and Q—Pilot Pressure
B—Bucket Dump Workport G—Bucket Rollback Pilot Boom Sections R—Return Pressure
C—C3 Shuttle Check H—Bleed to Outlet Section M—Bucket Dump Pilot S—Bucket Section—Boom
D—Compensator Assembly I—Load Sense to Boom N—High Pressure Raise and Bucket Dump
E—Bucket Rollback Workport Section O—Load Sense (Boom)
In combined operation with the boom valve some of higher boom regulated load sense pressure at that
the pressure conditions will be determined by what’s point.
happening in the boom valve. The metered load sense
is essentially blocked at C1 check (J) by the metered The pressure on the top (spring side of the
load sense from the boom valve. The regulated load compensator) is essentially boom load sense pressure,
sense in bridge passage flows up through the the same pressure that is acting on the boom
compensator, is blocked by the ball check and goes to compensator. Therefore, the flow to bucket dump
the boom compensator. It is also blocked at that point which requires very little pressure will be the same as
by the compensator check valve because of the much the boom which requires high pressure.
TX,05,SS3708 –19–07OCT03–2/2
9025
05
47

092005
PN=731
Theory Of Operation
Auxiliary Section—Operating And Boom Raise
E COMPENSATOR
ASSEMBLY
C3 G "B"
SHUTTLE F C2 WORKPORT
"A" CHECK D SHUTTLE
CIRCUIT CHECK
RELIEF AND WORKPORT C
ANTI-CAVITATION B H STEERING CIRCUIT
LOAD RELIEF AND
AUXILIARY SENSE B ANTI-CAVITATION
PILOT "A"
WORKPORT A I AUXILIARY
PILOT "B"
WORKPORT
N ORIFICE
CHECK J BLEED TO
O STROKE PLATE OUTLET O STROKE
ADJUSTER SECTION ADJUSTER
PLUNGER TO OUTLET, M L C1 CHECK PLUNGER
ASSEMBLY BUCKET K AUXILIARY LOAD ASSEMBLY
AND BOOM SENSE TO
SECTIONS BUCKET SECTION
9025
05
48
D
F
E
L
P HIGH PRESSURE
Q LOAD SENSE (BOOM)
B B
R LOAD SENSE (AUXILIARY)
S PILOT PRESSURE
T RETURN PRESSURE
–19–16APR99
T121086
T121086
U AUXILIARY SECTION - FUNCTION OPERATING AND BOOM RAISE

092005
PN=732
Theory Of Operation
A—Auxiliary Pilot (“A” F—C2 Shuttle Check L—C1 Check Q—Load Sense (Boom)
Workport) G—“B” Workport M—To Outlet Bucket and R—Load Sense (Auxiliary)
B—Circuit Relief and H—Steering Load Sense Boom Sections S—Pilot Pressure
Anti-Cavitation I—Auxiliary Pilot (“B’ O—Stroke Adjuster Plunger T—Return Pressure
C—“A” Workport Workport) Assembly U—Auxiliary Section—
D—C3 Shuttle Check J—Bleed to Outlet Section P—High Pressure Operation and Boom Raise
E—Compensator Assembly K—Auxiliary Load Sense to
Bucket Section
The auxiliary section of the loader control valve is a brings the pump into stroke. With the spool shifted,
closed center, pilot-operated, four-position, four-way trapped oil in the workport (B) will unseat the C3
spool type valve. Both workports are equipped with shuttle check (D) and is routed to the spring cavity of
screw adjustable circuit relief valves with anti-cavitation the compensator assembly (E). At this point the
protection (B). Several check valves in the valve compensator assembly is serving as the lift check,
section route the highest load sense signal to the pump discharge pressure has to build to a pressure
spring cavity of the compensator assembly. The that is slightly higher than workport pressure to open
compensator assembly (E) meters pump flow during the compensator valve. As pump discharge pressure
combined operation so that all functions will move at increases the compensator assembly will lift up and
the same time. It also serves as the lift check. allow oil to flow into the bridge passage to the head
end of the workport cylinders through the workport “A”.
The auxiliary section of the loader control valve are As the workport “A” cylinder extends, return oil from
equipped with spool stroke adjusters (O) in each end the rod end of the cylinder flows through the workport
cap. This allows the maximum auxiliary section flow to “B”across the auxiliary spool metering notches into the
be set anywhere from a few gallons per minute (gpm) return passage. The metering notches control the oil
to full pump flow. This is accomplished by controlling flow across the auxiliary spool to regulate the function
the maximum travel of the spool. Adjusting the spool speed. In combined operation with the boom valve
travel regulates the amount of flow area opened by the some of the pressure conditions will be determined by
spool. Since the hydraulic system is load sensing, what is happening in the boom valve. The metered
there is a set differential pressure across the opened load sense is essentially blocked at C1 check (L) by
inlet area. As a result, a flow proportional to this area the metered load sense from the boom valve. The
will be delivered to the implement. The stroke regulated load sense in bridge passage flows up
adjusters are set at full flow at the factory. Earlier through the compensator, is blocked by the ball check
models can add stroke adjusters for auxiliary valve and goes to the boom compensator. It is also blocked
sections by ordering through parts system. at that point by the compensator C2 shuttle check 9025
valve (F) because of the much higher boom regulated 05
When the auxiliary workport “A” function is activated, load sense pressure at that point. 49
pilot oil enters the end cap through auxiliary pilot
passage (A) and shifts the spool to the right against The pressure on the top (spring side of the
the centering springs. The greater the pilot pressure, compensator) is essentially boom load sense pressure,
the farther the spool will shift to the right. With the the same pressure that is acting on the boom
auxiliary spool shifted a load sense signal is compensator. Therefore, the flow to workport “B” which
immediately generated which unseats the C1 check requires very little pressure will be the same as the
valve (L) and is routed to the load sense valve which boom which requires high pressure.
CED,TX04577,844 –19–13OCT03–2/2

092005
PN=733
Theory Of Operation
Auxiliary Sections—Stroke Adjusters
–UN–14APR99
T121124
A—Set Screw (2 used) F—“A” Workport K—Back-Up Ring (2 used) O—Plunger— “A” Workport
B—Cartridge (2 used) G—“B” Workport L—O-Ring (2 used) P—Cap Screw (4 used)
C—End Cap (2 used) H—Stripper Bolt M—O-Ring (2 used) Q—Auxiliary Section—Stroke
D—Pilot Ports I—Plunger— “B” Workport N—O-Ring (2 used) Adjuster Assembly
9025
E—Spool J—Locking Hex Nut (2 used)
05
50
The auxiliary section of the loader control valve is controlling the maximum travel of the spool (E) by
equipped with spool stroke adjuster assembly (Q) in adjusting the plunger position in the end cap assembly
each end cap. Earlier models can add stroke adjusters with setscrew (A) and hex nut (J). Adjusting the spool
for auxiliary valve sections by ordering through parts travel regulates the amount of flow area opened by the
system and replacing the end caps. spool. Since the hydraulic system is load sensing,
there is a set differential pressure across the opened
The adjusters allow the maximum auxiliary section flow inlet area. As a result, a flow proportional to this area
to be set anywhere from a few gallons per minute will be delivered to the implement. The stroke
(gpm) to full pump flow. This is accomplished by adjusters are set at full flow at the factory.
CED,TX04577,849 –19–06JUN00–1/1

092005
PN=734
Theory Of Operation
Bucket Section Operation—Tool Carrier
BUCKET DUMP C3 SHUTTLE COMPENSATOR

B C CHECK D ASSEMBLY
CIRCUIT RELIEF WORK PORT
AND E BUCKET ROLLBACK
ANTI-CAVITATION WORK PORT
A F STEERING OR
AUXILIARY LOAD
BRIDGE SENSE
L
PASSAGE
BUCKET BLEED K BUCKET

H
DUMP M PASSAGE ROLLBACK G
LOAD SENSE PILOT
PILOT TO BOOM
I C1 CHECK
J SECTION
C
D TO OUTLET
I AUXILIARY
AND BOOM N HIGH PRESSURE
SECTIONS O LOAD SENSE
–19–19AUG97
P PILOT PRESSURE
A A
Q RETURN PRESSURE
T109464
T109464
R BUCKET SECTION - REGENERATIVE DUMP
A—Circuit Relief and F—Steering or Auxiliary Load J—To Outlet Auxiliary and O—Load Sense (Boom)
Anti-Cavitation Sense Boom Sections P—Pilot Pressure
B—Bucket Dump Workport G—Bucket Rollback Pilot K—Bleed Passage Q—Return Pressure
C—C3 Shuttle Check H—Load Sense to Boom L—Bridge Passage R—Bucket Section—
9025
D—Compensator Assembly Section M—Bucket Dump Pilot Regenerative Dump
05
E—Bucket Rollback Workport I—C1 Check N—High Pressure
51
The bucket section of the loader control valve is a The four positions of the Bucket control valve are:
closed center, pilot-operated, four-position, four-way
spool type valve. Both workports are equipped with • Neutral
screw adjustable circuit relief valves with anti-cavitation • Bucket Curl (Cylinder Retraction)
protection. Several check valves in the valve section • Bucket Dump (Cylinder Extension)
route the highest load sense signal to the spring cavity • Regenerative Dump
of the compensator assembly. This meters pump flow
during combined operation so all functions will move at
the same time. It also serves as the lift check.

092005
PN=735
Theory Of Operation
When the bucket dump function is activated, pilot oil cylinder flows through the bucket rollback workport (E),
enters the end cap through passage (M) and shifts the across the bucket spool metering notches into the
spool to the right against the centering springs. The return passage. The metering notches control the oil
greater the pilot pressure, the farther the spool will flow across the bucket spool to regulate the function
shift to the right. With the bucket spool shifted a load speed.
sense signal is immediately generated which unseats
the C1 check valve (J) and is routed to the load sense When the spool is moved to the regenerative dump
valve which brings the pump into stroke. With the position, both ends of the bucket cylinders are
spool shifted, trapped oil in the bucket dump work port connected by the bridge passage (L) in the control
(B) will unseat the C3 shuttle check (C) and is routed valve. Oil from the supply passage will flow to both
to the spring cavity of the compensator assembly (D). ends of the bucket cylinders. Since the head end of
At this point the compensator assembly is serving as the piston has a larger area than the rod end, a
the lift check, pump discharge pressure has to build to greater force is exerted on the head end causing the
a pressure that is slightly higher than workport cylinder to extend. As the cylinder extends, the oil
pressure to open the compensator valve. As pump returning from the rod end flows back to the valve and
discharge pressure increases the compensator combines with oil from the pump, and flows out to the
assembly will lift up and allow oil to flow into the bridge head end of the cylinder. This causes the cylinder to
passage to the head end of the bucket cylinders extend faster, which provides for a faster bucket dump
through the bucket dump workport (B). As the bucket cycle time.
cylinder extends, return oil from the rod end of the
TX,9025,ME478 –19–13OCT03–2/2
9025
05
52

092005
PN=736
Theory Of Operation
Outlet Section Operation
ISOLATION
VALVE B
C HIGHEST STEERING, AUXILIARY,
TO C3'S AND BOOM, OR BUCKET LOAD SENSE
COMPENSATOR FROM BOOM SECTION
VALVES A
END CUTAWAY LOAD SENSE

RELIEF VALVE
D
TO RETURN
FILTER L
ORIFICE K
STEERING
LOAD SENSE
J
G F FROM C1'S E BLEED FROM

C4 SHUTTLE H VALVE SECTIONS
LOAD SENSE TO
I ORIFICE CHECK
HYDRAULIC PUMP
M STEERING LOAD SENSE

9025
N RETURN PRESSURE 05
–19–19FEB97
53
T106964
O OUTLET SECTION - STEERING, LOADER IN NEUTRAL
T106964
A—To C3’s and Compensator D—Load Sense Relief Valve H—C4 Shuttle Check M—Steering Load Sense
Valves E—Bleed From Valve Sections I—Orifice N—Return Pressure
B—Isolation Valve F—From C1’s J—Steering Load Sense O—Outlet Section—Steering,
C—Highest Steering, Auxiliary, G—Load Sense to Hydraulic K—Orifice Loader in Neutral
Boom, or Bucket Load Pump L—To Return Filter
Sense From Boom Section
The outlet section functions as a control center for the • Load Sense Relief Valve (D)
load sense system. It also provides an outlet for the • Isolation Valve (B)
loader system return oil. • Shuttle Check Valve (H)
• Three Orifice Assembly (I)
The outlet section contains: • Single Orifice (K)

092005
PN=737
Theory Of Operation
The load sense relief valve limits load sense pressure loader functions that could otherwise bleed off through
thereby limiting maximum hydraulic system pressure. the load sense relief valve. Thus preventing a drift
When the pressure setting is reached, there is oil flow condition in the loader that could result from high
through orifice (K) and on through the relief valve to induced pressures.
return. The flow through orifice (K) causes a pressure
difference between the load sense port (G) to the The three orifice assemblies provides a bleed path for
pump and the steering (J) or C1 (F) load sense the load sense system when in neutral. This insures
coming from work load pressure. This pressure that there will be no residual pressure build-up,
difference is sensed at the pump control assembly consequent pump pressure, and flow increase in
relief valve. When the difference reaches the neutral.
differential pressure of the load sense valve the pump
destrokes to a point that maintains maximum system In a steering-loader-in-neutral operation, steering load
pressure. The maximum hydraulic system is set by the sense flows to C4 (H) seats it, goes through orifice (K)
load sense relief valve (D) adjustment. to the isolation valve. It is directed out port (G) to the
hydraulic pump. Steering load sense also flows into
The isolation valve is a free floating spool that senses the control valve inlet section. From there it flows a
the highest of the regulated load sense pressures form passage through each of the valve sections to the top
the hydraulic system components on the top area. The area (C) of the isolation valve. The isolation valve will
bottom area senses the pressure going to section C3’s now shuttle and send a signal to all the compensators
and compensator valves. The highest metered load (A).
sense from orifice (K) flows to the center area and
through a drilled passage to the bottom area. When Should any of the loader functions be operated, load
bottom area pressure is equal to or slightly higher the sense from the C1’s (F) will seat C4 (H) in the
spool shifts up until the center area just reaches into opposite direction if higher than steering load sense,
the return area. At this point the spool will shuttle and have no affect if lower. The highest load sense
slightly and maintain the center are pressure equal to pressure will always be in control both at the hydraulic
that on the top area. and in the loader control valve.
The isolation spool also functions as an anti-drift valve

by blocking high induced pressures from any of the
9025
05
54
TX,05,SS3709 –19–13OCT03–2/2

092005
PN=738
Theory Of Operation
Load Sense Circuit—Steering

LOAD SENSE
A
FROM STEERING
COMPENSATOR ISOLATION
B C
VALVES SPOOL
INLET I
D
H G F E LOAD SENSE
AUXILIARY BUCKET BOOM ORIFICES TO PUMP
9025
05
55
J HIGH PRESSURE
K STEERING LOAD
SENSE PRESSURE
L RETURN PRESSURE
–19–19FEB97
M LOAD SENSE CIRCUIT - STEERING

T107006
T107006
A—Load Sense from Steering E—Orifices I—Inlet L—Return Pressure

B—Compensator Valves F—Boom J—High Pressure M—Load Sense Circuit—
C—Isolation Spool G—Bucket K—Steering Load Sense Steering
D—Load Sense to Pump H—Auxiliary Pressure

092005
PN=739
Theory Of Operation
The load sense pressure signal (A) enters the loader the spool, out the port (D) to the hydraulic pump as a
control at two points; the inlet section and the outlet pump output control signal. At the isolation spool it
section. From the inlet section it is channeled to the also flows to the bottom area. The isolation spool
compensator valve (B) in each section and then on to shuttles and sends load sense to the spring side area
the top area of the isolation spool (C). In the outlet of each compensator. With all the loader functions in
section it seats the ball shuttle and flows through the neutral, there is no effect on any of the loader circuits.
single orifice (E) to the isolation spool. It goes around
TX,9025,ME339 –19–13FEB97–2/2
9025
05
56

092005
PN=740
Theory Of Operation
Load Sense Circuit—Steering And Boom Down

LOAD SENSE
A
FROM STEERING
COMPENSATOR ISOLATION
B C
VALVES SPOOL
INLET I
D
H G F E LOAD SENSE
9025
05
J HIGH PRESSURE 57
K STEERING LOAD
SENSE PRESSURE
L BOOM LOAD
SENSE PRESSURE
M LOW PRESSURE
–19–19FEB97
N LOAD SENSE CIRCUIT - STEERING & BOOM DOWN

T107007
T107007
A—Load Sense from Steering F—Boom J—High Pressure M—Low (Return) Pressure
B—Compensator Valves G—Bucket K—Steering Load Sense N—Load Sense Circuit—
C—Isolation Spool H—Auxiliary Pressure Steering and Boom Down
D—Load Sense to Pump I—Inlet L—Boom Load Sense
E—Orifices Pressure

092005
PN=741
Theory Of Operation
The steering load sense signal enters the load control load sense from the boom check ball to the shuttle
valve in the same way as with steering only activated. check will seat the shuttle check to the right and the
With a compensator in the boom circuit steering load higher load sense pressure will be used at the isolation
sense pressure is directed to the top spring area of the spool. The highest load sense pressure will be utilized
compensator (B). The boom compensator will now by both the hydraulic pump control unit and the
restrict oil flow out the boom down work port, thereby compensator valves (B).
providing priority oil flow to steering.
If for example, boom raise was operated while steering

and boom pressures were higher than steering, then
TX,9025,ME340 –19–13FEB97–2/2
9025
05
58

092005
PN=742
Theory Of Operation
Load Sense Circuit—Boom Raise And Bucket Dump
A LOAD SENSE
FROM STEERING COMPENSATOR ISOLATION
B C
VALVES SPOOL
INLET I
D
H G F E LOAD SENSE
J HIGH PRESSURE
K BOOM LOAD
9025
SENSE PRESSURE
–19–23APR99
05
L BUCKET LOAD 59
SENSE PRESSURE
M RETURN PRESSURE
T121292
T121292
N LOAD SENSE CIRCUIT - BOOM RAISE & BUCKET DUMP
A—Load Sense from Steering F—Boom J—High Pressure M—Return Pressure

B—Compensator Valves G—Bucket K—Boom Load Sense N—Load Sense Circuit—Boom
C—Isolation Spool H—Auxiliary Pressure Raise and Bucket Dump
D—Load Sense to Pump I—Inlet L—Bucket Load Sense
E—Orifices Pressure
Without any flow control when operating boom raise boom load sense pressure to the top side of the
and bucket dump, all of the pump output would go to bucket compensator. Now both bucket and boom
the bucket dump circuit. With compensators in the compensators have the same spring side pressure.
loader circuits, the bucket compensator will restrict flow Thus, the flow past each compensator is the same
so that equal flow will go to boom raise and bucket though the bucket dump workport pressure is very low.
dump. This is accomplished by sending the higher
TX,9025,ME341 –19–13FEB97–1/1

092005
PN=743
Theory Of Operation
Load Sense Relief Valve Operation

1 4 3 5
The load sense relief valve is a direct acting poppet (3)
type design located in the loader control valve outlet
section.
–UN–17OCT03
Its function is to limit the maximum pressure in the
hydraulic system. It actually senses and limits load sense
pressure. Setting a limit on load sense pressure also sets
a limit on pump output or system pressure. This pressure 2
T195537
level will normally be differential pressure plus the setting
of the load sense relief valve.
1—Adjustment Screw
To adjust, a hydraulic function is bottomed, the pump 2—Body
output pressure is monitored and the adjustment screw (1) 3—Poppet
is turned to set the pressure reading to the specified 4—Spring
maximum value. Turn adjustment screw in to increase and 5—Inlet Screen
out to decrease pressure.
TX,05,SS3731 –19–13OCT03–1/1
9025
05
60

092005
PN=744
Theory Of Operation
Relief Valve Operation
A RETURN
A
B INLET
C POPPET
NORMAL OPERATION D FLOATING B
SEAT
ADJUSTER E RETURN A
A
B INLET
–19–03SEP96
PLUNGER F RELIEF OPERATION G RELIEF PRESSURE
H OPERATING PRESSURE
J RELIEF VALVE
T102057
T102057 I RETURN PRESSURE
A—Return D—Floating Seat G—Relief Pressure I—Return Pressure

B—Inlet E—Adjuster H—Operating Pressure J—Relief Valve
C—Poppet F—Plunger
The loader hydraulic system uses a direct-acting relief When a pressure spike occurs and exceeds the relief
valve located in the inlet port plate of the loader control setting, pressure oil in the inlet forces the snubber and
valve assembly. Its function is to relieve pressures floating seat open against the spring. The plunger
9025
spikes that result from abrupt flow changes. remains stationary where it maintains a volume of oil 05
on the right of the snubber orifice. The snubber orifice 61
During normal operation, loader pressures are below dampens the movement of the floating seat. The relief
the relief pressure of the relief valve. The floating seat pressure is adjusted by the position of the adjuster (E).
(D) and snubber remain seated against the poppet (C),
sealing inlet (B) oil from the return (A) passage.
TX,05,SS3730 –19–28AUG96–1/1

092005
PN=745
Theory Of Operation
Circuit Relief Valve Operation
B RETURN
B A
D
WORKPORT A
G
POPPET D
C
SEAT B A
H NORMAL OPERATION
B RETURN
E
WORKPORT WORKPORT B RETURN
A A
F G PILOT D
PIN POPPET POPPET
I PILOT OPERATION J RELIEF OPERATION
K RELIEF PRESSURE
L OPERATING PRESSURE
–19–09OCT97
9025
05 M RETURN PRESSURE
62
N CIRCUIT RELIEF VALVE
T6567OU
T6567OU (WITH ANTI-CAVITATION)
A—Workport E—Return Passage I—Pilot Operation M—Return Pressure

B—Return F—Pin J—Relief Operation N—Circuit Relief Valve (With
C—Seat G—Pilot Poppet K—Relief Pressure Anti-Cavitation)
D—Poppet H—Normal Operation L—Operating Pressure
The bucket rollback and dump, and both auxiliary As the circuit pressures approach the relief pressure
workports of the loader control valve use a setting, the pin (F) forces the pilot poppet (G) off its
pilot-operated circuit relief with an anti-cavitation seat. Grooves cut into the pin, bleed oil on the right
feature. side of the poppet to return through the pilot poppet.
During normal operation (H), the poppet (D) is

positioned against the seat (C) to seal the workport (A)
oil from the return (B) passage.

092005
PN=746
Theory Of Operation
During relief operation (J), oil on the right side of the pressure oil flows from the workport to return across
poppet is drained to return causing pressure in the the poppet.
workport to overcome the poppet spring force. Relief
9025
05
63

092005
PN=747
Theory Of Operation
B RETURN
WORKPORT A
B A
C POPPET
F NORMAL
OPERATION
B RETURN
B A
WORKPORT A
9025 D PIN E SPRING

05
64 G ANTI-CAVITATION
OPERATION
–19–26AUG97
H RETURN PRESSURE
I LOW PRESSURE
G CIRCUIT RELIEF VALVE
(WITH ANTI-CAVITATION) T6567OV
T6567OV
A—Workport C—Poppet E—Spring G—Circuit Relief Valve (With

B—Return D—Pin F—Anti-Cavitation Operation Anti-Cavitation)
If the workport pressure in the circuit drops below During normal operation (F), the poppet (C) remains
return pressure, the anti-cavitation feature of the circuit closed against its seat causing the workport (A) to be
relief valve activates. sealed from the return (B) passage.

092005
PN=748
Theory Of Operation
If cavitation occurs, the oil pressure in the workport shoulder of the poppet to force it open against the
and in the spring (E) area of the poppet drops below spring.
return pressure. Return pressure oil works against the
TX,9025,SS3796 –19–07OCT03–4/4
Anti-Cavitation Valve Operation
RETURN A
WORKPORT
B A B
POPPET C NORMAL OPERATION
RETURN A
B A B
D PRESSURE OIL
–19–21APR99
ANTI-CAVITATION OPERATION E RETURN OIL
9025
F CAVITATION 05
T121234
T121234
G ANTI-CAVITATION VALVE OPERATION PRESSURE OIL 65
A—Return C—Poppet E—Return Oil G—Anti-Cavitation Valve

B—Workport D—Pressure Oil F—Cavitation Pressure Oil Operation
The boom section of the loader control valve contains If cavitation occurs, the oil pressure in the workport (B)
an anti-cavitation valve in boom down and a plug in and in the spring area on the backside of the poppet
the boom raise workport. If workport pressure in the will drop. With workport pressure below return
circuit drops below return pressure, the anti-cavitation pressure, the return pressure works against the
valve will open and return pressure oil will flow into the shoulder area of the poppet (C) causing it to open
workport. against the spring. Return pressure oil flows into the
workport to prevent cylinder cavitation.
During normal operation, the poppet (C) is held against
the seat by spring force plus workport pressure acting
on the backside of the poppet. With the poppet seated,
the workport (B) is sealed from the return passage.
TX,05,SS3733 –19–07OCT03–1/1

092005
PN=749
Theory Of Operation
Return Filter Operation

INLET A
CHECK BYPASS
VALVE VALVE BYPASS OUTLET
4 VALVE 5 CHECK
2 3 SPRING VALVE
1
MAIN
INLET 6 OUTLET
FILTER 7
A
COOLER
OUTLET SWITCH
8 9
9025
05
66
–19–08OCT03
10 RETURN OIL
SECTION A-A
T195407
T195407 11 HYDRAULIC FILTER - NORMAL OPERATION
1—Main Inlet 4—Bypass Valve Spring 7—Filter 10—Return Oil

2—Inlet Check Valve (Optional) 5—Outlet Check Valve 8—Cooler Outlet 11—Hydraulic Filter-Normal
3—Bypass Valve 6—Outlet 9—Switch Operation
Continued on next page TX04577,0000434 –19–07OCT03–1/4

092005
PN=750
Theory Of Operation
Return Filter Operation—Normal opens when the pressure increases enough to

overcome the force of the inlet check valve spring. The
The hydraulic filter assembly removes contaminants oil flows into the filter element (7) then to the outlet
from the hydraulic system return oil (10), produces pressure check valve (5). The outlet pressure check
inlet back-pressure, and regulates outlet back-pressure valve forces flow through the cooler outlet (8) port to
which forces flow through the hydraulic oil cooler. The the oil cooler. When the restriction in the oil cooler
filter housing contains an (optional) inlet check valve becomes high enough to overcome outlet pressure
(2), bypass valve (3), filter restriction switch (9), and an plus the set spring force of the outlet check valve (5),
outlet pressure check valve (5). Return oil (10) flows the outlet valve opens and allows oil to return to the
from the loader valve and steering valve return into the reservoir. Pressure on the inlet side of the filter
main and auxiliary inlet (1). The oil then flows through element is sensed on the left side of the bypass valve
the inlet check valve (2), through the filter element (7), (3). Any pressure at the filter outlet due to line
through the auxiliary outlet (8) to the cooler (if restriction is sensed on the right side of the bypass
equipped) or through the outlet check valve (5), and valve (3). Pressure in the outlet passage and the
then through the main outlet (6) to the reservoir. by-pass spring (4) force, hold the bypass valve closed
Pressure on the inlet side of the filter assembly is unless there is a restriction in the oil filter due to being
sensed on the left side of the inlet valve (2). The valve clogged.
9025
05
67

092005
PN=751
Theory Of Operation
A
HIGH BYPASS BYPASS
PRESSURE VALVE 6 VALVE
PASSAGE 4 SPRING TO
5 RESERVOIR
1
MAIN
INLET 7 OUTLET
2 FILTER 3 8 LOW PRESSURE

COOLER PASSAGE
INLET
A
COOLER
OUTLET SWITCH
9 10
SWITCH
SPRING
11
12
SWITCH
PISTON
9025
05
68
–19–08OCT03
13 RETURN OIL PRESSURE 5 HIGH PRESSURE
14 RESTRICTED OIL PRESSURE PASSAGE
SECTION A-A 8 LOW PRESSURE T195408
PASSAGE
T195408 15 HYDRAULIC FILTER - RESTRICTED OPERATION
1—Main Inlet 6—Bypass Valve Spring 10—Switch 14—Restricted Oil Pressure

2—Cooler Inlet 7—Outlet 11—Switch Spring 15—Hydraulic Return Filter
3—Filter 8—Low Pressure Passage 12—Switch Piston Operation—Restricted
4—Bypass Valve 9—Cooler Outlet 13—Return Oil Operation
5—High Pressure Passage

092005
PN=752
Theory Of Operation
Return Filter Operation—Restricted low-pressure passage (8), plus a set spring (11) force
in the switch, the piston (12) moves up (closes)
As the filter starts to plug or when the oil is cold, providing a ground for the filter restriction indicator.
pressure at the inlet side of the filter element The switch will cause the filter restriction indicator light
increases. When the filter becomes restricted to the to illuminate. The indicator switch is set to close 10 psi
point where pressure at the filter element inlet before the bypass valve (4) opens allowing the
increases enough to overcome outlet pressure plus a operator to perform maintenance on the hydraulic
set spring force (6), the bypass valve opens allowing system before the unclean oil passes through the
unfiltered oil to flow to the oil cooler or to the reservoir. hydraulic oil system.
The filter restriction indicator switch (10) works on the Under normal operation, the restriction indicator light
same principle as the filter bypass valve. will glow when operating the hydraulic functions with
High-pressure oil is sensed through the high-pressure cold oil. If the restriction indicator light continues to
passage (1). Restricted oil (14) caused by a clogged glow after the oil reaches operating temperature, the
filter or cold oil will create higher oil pressure on the return filter is being bypassed. Extended operation in
inlet side of the filter element. When this inlet pressure the bypass mode will cause damage to the hydraulic
overcomes the outlet pressure, sensed by the system.
TX04577,0000434 –19–07OCT03–4/4
9025
05
69

092005
PN=753
Theory Of Operation
Ride Control Operation
1 2
ROD HEAD
3
5 6
9
8
7
6
4
–UN–25SEP01
TANK ACC ACC TEST
13 TRAPPED OIL
12 11 10
14 RETURN OIL
T145248
15 HIGH PRESSURE OIL
T145248
1—Rod Port 5—High Flow Valve 9—Solenoid Valve (on/off) 12—Tank Port
2—Head Port 6—Check Valve (2 used) (Y32) 13—Trapped Oil
3—Solenoid Valve (on/off) 7—Shuttle Valve 10—Accumulator Test Port 14—Return Oil
(Y18) 8—Bucket Dump Solenoid 11—Accumulator Port 15—High Pressure Oil
9025 4—Low Flow Valve Valve (Y17)
05
70
On Position Then flow is through the shuttle valve (7). When head
pressure overcomes accumulator pressure the shuttle
In the on position with the engine running, the on/off shifts to allow pilot operated low flow valve (4) and
solenoids (3 and 9) are activated. Pressure spikes high flow valve (5) are open and allow flow to and from
from the boom cylinder head end can flow into the the accumulator (11).
accumulator two ways, through the low flow valve (4)
and the high flow valve (5). This provides a smooth In the on position, the boom cylinder rod end (1) is
engagement when ride control is turned on. open to return. Oil is free to flow in and out of the rod
end, therefore the boom cannot be powered down
When pressure oil in the accumulator is greater than while ride control is on. Ride control can be left
pressure in the boom cylinder head end, check valves engaged during bucket loading, but may be turned off
(6) are held on there seat by accumulator pressure. if a more rigid operation is desired.

092005
PN=754
Theory Of Operation
While in the on position, if the bucket dump function is wheel loaders with the Z-Bar linkage. With ride control
activated, ride control will momentarily be shut off. A either on or off while dumping the bucket, the partial
pressure switch in the bucket dump pilot circuit closes lowering of the boom cylinders is reduced.
and powers the bucket dump solenoid (8). When this
solenoid is on, oil in the boom cylinder head end can See Ride Control Circuit Theory Of Operation (S.N. —
not flow into the accumulator. When the bucket is in 590067) (Group 9015A-15) or See Flex Load
the fully dumped position, the bucket cylinder transmits Controller (FLC) Circuit Theory of Operation (S.N.
forces through the Z-Bar linkage which can cause the 590068— ) (Group 9015B-15) for electrical circuit
boom cylinders to partially retract. This is common to information.
9025
05
71

092005
PN=755
Theory Of Operation
1 2
ROD HEAD
3
5 6
9
7
8
6
4
–UN–14SEP01
TANK ACC ACC TEST
13 TRAPPED OIL
12 11 10
14 RETURN OIL
T145006
15 HIGH PRESSURE OIL
T145006
1—Rod Port 5—High Flow Valve 9—Solenoid Valve (on/off) 12—Tank Port
2—Head Port 6—Check Valve (2 used) (Y32) 13—Trapped Oil
3—Solenoid Valve (on/off) 7—Shuttle Valve 10—Accumulator Test Port 14—Return Oil
(Y18) 8—Bucket Dump Solenoid 11—Accumulator Port 15—High Pressure Oil
4—Low Flow Valve Valve (Y17)
9025 Off Position valves (6) will trap the oil in the pilot circuit to the high
05
flow valve (5) from the signal received from the shuttle
72
In the off position the (on/off) solenoids (3 and 9) are valve (7) that reads the highest pressure differential.
de-energized.
See Ride Control Circuit Theory Of Operation (S.N. —
In this mode the accumulator will charge to the highest 590067) (Group 9015A-15) or See Flex Load
boom raise pressure. Oil flow will be through the low Controller Circuit Theory of Operation (S.N. 590068— )
flow valve (4) and high flow valve (5) whenever head (Group 9015B-15) for electrical circuit information.
pressure is more than accumulator pressure. Check
TX04577,0000427 –19–13OCT03–3/3

092005
PN=756
Group 15
Hydraulic Circuit Symbols
9025
15
1
–19–28SEP89
TS700
TX,15,WW2279 –19–20AUG96–1/1

092005
PN=757
Hydraulic System Schematics

T159052 –19–17SEP02
LS RELIEF
STEERING VALVE 3 X .031
STEERING CYLINDERS
PVG 120/130 HYDRAULIC PUMP COMPENSATOR
RIDE CONTROL
RETURN
FILTER
COMPENSATOR
LS
LS PRESSURE
RELIEF BOOM
VALVE SECONDARY STEERING RIDE
VALVE
CONTROL
PRESSURE
CYLINDERS
SWITCH
60
PSI
NC
PRESSURE REDUCING VALVE MODULE
HYDRAULIC
FAN DRIVE PILOT ENABLE BUCKET
PRV/SOURCE VALVE
CYLINDER
(625 PSI)
AXLE
RECIRCULATING PUMP COMPENSATOR
MOTOR PRESSURE REGULATED
DUAL PRESSURE
PUMP
DIFF
LOCK
BOOM
165 DOWN
OIL PSI
LEFT RIGHT (OIL
BRAKE
COOLER N2 LIGHTS COOLER
(60 PSI) - FIELD
OPTION) AUXILIARY
RELIEF VALVE CYLINDERS
AXLE
DISCONNECT
LOADER CONTROL VALVE

165
PSI PILOT CONTROLLER
N2
1 PSI
FILL
SCREEN
PIN
NC 300 DISCONNECT LOW PRESSURE OIL
BREATHER
PSI
PILOT CONTROL OIL
TRAPPED OIL
AUXILIARY
CONTROLLER RETURN OIL
T159052
Hydraulic System Schematic—Neutral (S.N. —590067)
TX,9025,HH184 –19–29NOV04–1/5

092005
PN=758
9025-15-2 - A 9025-15-2 - B 9025-15-2 - C
STEERING
PVG 120/130 HYDRAULIC PUMP
RETURN
FILTER
LS
LS PRESSURE
RELIEF
VALVE VALVE SECONDARY STEERING
PRESSUR
HYDRAULIC
FAN DRIVE
AXLE
RECIRCULATING PUMP
MOTOR PRESSURE
DUAL
PUMP
OIL
165
PSI
LEFT RIGHT (OIL
BRAKE
(60 PSI) - FIELD
OPTION)
165
PSI
N2
1 PSI
FILL
SCREEN
NC 300
BREATHER
PSI
T159052
9025-15-2 - A
Hydraulic System
T159052 –19–17SEP02
LS RELIEF
RING VALVE 3 X .031
STEERING CYLINDERS
COMPENSATOR
COMPENSATOR
RIDE BOOM
CONTROL
PRESSURE
CYLINDERS
SWITCH
60
PSI
NC
SSURE REDUCING VALVE MODULE
PILOT ENABLE BUCKET
PRV/SOURCE VALVE
CYLINDER
(625 PSI)
COMPENSATOR
REGULATED
PRESSURE
DIFF
LOCK
BOOM
DOWN
AUXILIARY
AXLE
DISCONNECT

PILOT CONTROLLER
PIN
DISCONNECT
AUXILIARY
CONTROLLER
TM2075 (03MAR05)
9025-15-2 - B
em Schematics
RIDE CONTROL
KET
NDER
LOW PRESSURE OIL

PILOT CONTROL OIL
TRAPPED OIL
RETURN OIL
Hydraulic System Schematic—Neutral (S.N. —590067)

TX,9025,HH184 –19–29NOV04–1/5
9025-15-2 644J and 724J Loader

092005
PN=758
9025-15-2 - C
9025-15-2 - Blank
T159055 –19–29OCT02
STEERING VALVE
LS RELIEF
3 X .031
STEERING CYLINDERS
RIDE CONTROL
RETURN
FILTER
COMPENSATOR
LS
LS PRESSURE
RELIEF RIDE BOOM
CONTROL
PRESSURE CYLINDERS
SWITCH
60
PSI
NC
HYDRAULIC
PRV/SOURCE VALVE
CYLINDER
(625 PSI)
AXLE
RECIRCULATING PUMP COMPENSATOR
MOTOR PRESSURE REGULATED
DUAL PRESSURE
PUMP
DIFF
LOCK
BOOM
165 DOWN
OIL PSI
LEFT RIGHT
BRAKE (OIL
(60 PSI) - FIELD
OPTION) AUXILIARY
AXLE
DISCONNECT

165
PSI PILOT CONTROLLER
N2
1 PSI
PRESSURE OIL
FILL
SCREEN LOAD SENSE OIL
NC 300 PIN
BREATHER DISCONNECT LOW PRESSURE OIL
PSI
PILOT CONTROL OIL
AUXILIARY
TRAPPED OIL
CONTROLLER
RETURN OIL
T159055
Hydraulic System Schematic—Steering (S.N. —590067)
TX,9025,HH184 –19–29NOV04–2/5

092005
PN=759
9025-15-3 - A 9025-15-3 - B 9025-15-3 - C
T159055 –19–29OCT02
RETURN
FILTER
LS
LS PRESSURE
RELIEF
VALVE VALVE
HYDRAULIC
FAN DRIVE
AXLE
RECIRCULAT
MOTOR
DUAL
PUMP
OIL
165
PSI
LEFT RIGHT
COOLER N2
165
PSI
N2
1 PSI
FILL
SCREEN
NC 300
BREATHER
PSI
T159055
Hydraulic System Schematic—Steering (S.N. —590067)
TX,9025,HH184 –19–
TM2075 (03MAR05) 9025-15-3 644J and 72
9025-15-3 - A
STEERING VALVE
LS RELIEF
3 X .031
STEERING CYLINDERS
COMPENSATOR
COMPENSATOR
URE
SECONDARY STEERING RIDE
CONTROL
PRESSURE
SWITCH
60
PSI
NC
PILOT ENABLE
PRV/SOURCE VALVE
(625 PSI)
CULATING PUMP COMPENSATOR

R PRESSURE REGULATED
PRESSURE
DIFF
LOCK
BOOM
DOWN
BRAKE (OIL
LIGHTS COOLER
(60 PSI) - FIELD
OPTION)
RELIEF VALVE
AXLE
DISCONNECT

PILOT CONTROLLER
PIN
DISCONNECT
AUXILI
CONTR
4 –19–29NOV04–2/5
nd 724J Loader
092005
PN=759
9025-15-3 - B
RIDE CONTROL
BOOM
CYLINDERS
BUCKET
CYLINDER
AUXILIARY
CYLINDERS
PRESSURE OIL
LOAD SENSE OIL
LOW PRESSURE OIL
PILOT CONTROL OIL
AUXILIARY
TRAPPED OIL
CONTROLLER
RETURN OIL
9025-15-3 - C
9025-15-3 - Blank
T159053 –19–17SEP02
LS RELIEF
STEERING VALVE
3 X .031
STEERING CYLINDERS
RIDE CONTROL
RETURN
FILTER
COMPENSATOR
LS
LS PRESSURE
RELIEF RIDE BOOM
CONTROL
PRESSURE CYLINDERS
SWITCH
60
PSI
NC
HYDRAULIC
PRV/SOURCE VALVE
CYLINDER
(625 PSI)
AXLE
RECIRCULATING COMPENSATOR
PUMP REGULATED
MOTOR PRESSURE
DUAL PRESSURE
PUMP
DIFF
LOCK
BOOM
165 DOWN
PSI
LEFT RIGHT (OIL
OIL BRAKE
(60 PSI) - FIELD
OPTION) AUXILIARY
AXLE
DISCONNECT
LOADER CONTROL VALVE PRESSURE OIL
165
PSI PILOT CONTROLLER LOAD SENSE OIL
N2
(STEERING)
1 PSI
FILL
LOAD SENSE OIL
SCREEN (BOOM)
PIN
NC 300 DISCONNECT
BREATHER LOW PRESSURE OIL
PSI
PILOT CONTROL OIL

TRAPPED OIL
AUXILIARY
CONTROLLER RETURN OIL
T159053
Hydraulic System Schematic—Steering and Boom Down (S.N. —590067)
TX,9025,HH184 –19–29NOV04–3/5

092005
PN=760
9025-15-4 - A 9025-15-4 - B 9025-15-4 - C
STEERIN
RETURN
FILTER
LS
LS PRESSURE
RELIEF
PRESSU
HYDRAULIC
FAN DRIVE
AXLE
RECIRCULATING PUMP
MOTOR PRESSURE
DUAL
PUMP
165
PSI
LEFT RIGHT (OIL
OIL BRAKE
(60 PSI) - FIELD
OPTION)
165
PSI
N2
1 PSI
FILL
SCREEN
NC 300
BREATHER
PSI
T159053
9025-15-4 - A
T159053 –19–17SEP02
LS RELIEF
ERING VALVE
3 X .031
STEERING CYLINDERS
COMPENSATOR
COMPENSATOR
RIDE BOOM
CONTROL
PRESSURE CYLINDERS
SWITCH
60
PSI
NC
ESSURE REDUCING VALVE MODULE
PILOT ENABLE BUCKET
PRV/SOURCE VALVE
CYLINDE
(625 PSI)
COMPENSATOR
REGULATED
E PRESSURE
DIFF
LOCK
BOOM
DOWN
AUXILIARY
AXLE
DISCONNECT
LOADER CONTROL VALVE PR
PILOT CONTROLLER LO
(ST
LO
PIN
(BO
DISCONNECT
LO
PIL
TR
AUXILIARY
CONTROLLER RE
TM2075 (03MAR05)
9025-15-4 - B
RIDE CONTROL
KET
NDER
PRESSURE OIL
LOAD SENSE OIL
(STEERING)
LOAD SENSE OIL
(BOOM)
LOW PRESSURE OIL
PILOT CONTROL OIL
TRAPPED OIL
RETURN OIL
Hydraulic System Schematic—Steering and Boom Down (S.N. —590067)
TX,9025,HH184 –19–29NOV04–3/5
9025-15-4 644J and 724J Loader

092005
PN=760
9025-15-4 - C
9025-15-4 - Blank
T159054 –19–17SEP02
LS RELIEF
STEERING CYLINDERS COMPENSATOR

RIDE CONTROL
RETURN
FILTER
COMPENSATOR
LS
LS PRESSURE
RELIEF
VALVE SECONDARY STEERING RIDE BOOM
VALVE CONTROL
PRESSURE
CYLINDERS
SWITCH
60
PSI
NC
HYDRAULIC BUCKET
FAN DRIVE PILOT ENABLE
PRV/SOURCE VALVE
CYLINDER
(625 PSI)
AXLE
PUMP COMPENSATOR
RECIRCULATING
PRESSURE REGULATED
MOTOR
PRESSURE
DUAL
PUMP
DIFF
LOCK
BOOM
165 DOWN
OIL PSI
LEFT RIGHT
BRAKE (OIL
(60 PSI) - FIELD
OPTION) AUXILIARY
AXLE
DISCONNECT
LOADER CONTROL VALVE PRESSURE OIL

165
PSI PILOT CONTROLLER LOAD SENSE OIL
N2
(BOOM)
1 PSI
FILL
LOAD SENSE OIL
SCREEN (BUCKET)
NC 300 PIN
BREATHER DISCONNECT LOW PRESSURE OIL
PSI
PILOT CONTROL OIL

AUXILIARY
TRAPPED OIL
CONTROLLER
RETURN OIL
T159054
Hydraulic System Schematic—Boom Raise and Bucket Dump (S.N. —590067)
TX,9025,HH184 –19–29NOV04–4/5

092005
PN=761
9025-15-5 - A 9025-15-5 - B 9025-15-5 - C
T159054 –19–17SEP02
RETURN
FILTER
LS
LS PRESSURE
RELIEF
VALVE VALVE
HYDRAULIC
FAN DRIVE
AXLE
RECIRCULA
MOTOR
DUAL
PUMP
OIL
165
PSI
LEFT RIGHT
COOLER N2
165
PSI
N2
1 PSI
FILL
SCREEN
NC 300
BREATHER
PSI
T159054
Hydraulic System Schematic—Boom Raise and Bucket Dump (S
TX,9025,HH184 –19–
TM2075 (03MAR05) 9025-15-5 644J and 72
9025-15-5 - A
LS RELIEF
STEERING CYLINDERS COMPENSATOR
COMPENSATOR
SSURE
SECONDARY STEERING RIDE
CONTROL
PRESSURE
SWITCH
60
PSI
NC
PILOT ENABLE
PRV/SOURCE VALVE
(625 PSI)
E
PUMP COMPENSATOR
RCULATING
PRESSURE REGULATED
OR
PRESSURE
L
P
DIFF
LOCK
BOOM
DOWN
T
BRAKE (OIL
LIGHTS COOLER
(60 PSI) - FIELD
OPTION)
RELIEF VALVE
AXLE
DISCONNECT

PILOT CONTROLLER
PIN
DISCONNECT
AUXIL
CONT
mp (S.N. —590067)
4 –19–29NOV04–4/5
nd 724J Loader
092005
PN=761
9025-15-5 - B
RIDE CONTROL
BOOM
CYLINDERS
BUCKET
CYLINDER
AUXILIARY
CYLINDERS
PRESSURE OIL
LOAD SENSE OIL
(BOOM)
LOAD SENSE OIL

(BUCKET)
LOW PRESSURE OIL
PILOT CONTROL OIL
AUXILIARY
TRAPPED OIL
CONTROLLER
RETURN OIL
9025-15-5 - C
9025-15-5 - Blank
T204478 –19–01NOV04
33 OUTLET SECTION
6 FAN REVERSING 7 HYDRAULIC 22 STEERING
VALVE FAN DRIVE VALVE 23 30 RIDE CONTROL
LOADER VALVE
CONTROL
10 SECONDARY VALVE
STEERING
VALVE
25
BOOM
11 SECTION
LOAD SENSE
8 HYDRAULIC PRESSURE
RETURN 9 TEST PORT
FILTER MAIN M
HYDRAULIC
PUMP
DUAL PUMP AXLE

RECIRCULATING 18 PUMP OUTLET
20 PRESSURE
PRESSURE
MOTOR 13 REDUCING
TEST PORT
VALVE 29 RIDE CONTROL
19 ACCUMULATOR
26 BUCKET SECTION
REGULATED
PRESSURE
TEST
PORT
31
17 BOOM
AXLE DOWN
12 HYDRAULIC 14 OIL ACCUMU- 27 AUXILIARY SECTION
OIL COO- LATOR
BRAKE
COOLER ACCUMU- LER
LATOR
32 INLET SECTION
15
28 AUXILIARY
BRAKE
ACCUMU- FUNCTION
24 PILOT CONTROL
LATOR PILOT
CONTROL 1 LOW PRESSURE OIL
16 BRAKE VALVE 2 LOAD PRESSURE SENSE OIL
3 REGULATED PRESSURE OIL
21 PIN/AXLE
DISCONNECT 4 TRAPPED OIL
VALVE
5 RETURN OIL
T204478
Hydraulic System Schematic—Neutral (S.N. 590068—)
TX,9025,HH184 –19–29NOV04–5/5

092005
PN=762
9025-15-6 - A 9025-15-6 - B 9025-15-6 - C
6 FAN REVERSING 7 HYDRAULIC
VALVE FAN DRIVE
10 SECONDAR
STEERING
VALVE
11
LOAD SENSE
8 HYDRAULIC PRESSURE
RETURN 9 TEST PORT
FILTER MAIN M
HYDRAULIC
PUMP
DUAL PUMP AXLE

RECIRCULATING 18 PUMP
MOTOR 13 PRESS
TEST
31
17 BOOM
AXLE DOWN
12 HYDRAULIC 14 OIL ACCUMU-
OIL COO- LATOR
BRAKE
COOLER ACCUMU- LER
LATOR
15
BRAKE
ACCUMU-
LATOR
16 BRAKE VALVE
T204478
9025-15-6 - A
T204478 –19–01NOV04
33 OUTLET SECTION
22 STEERING
VALVE 23
LOADER
CONTROL
DARY VALVE
NG
25
BOOM
SECTION
UMP OUTLET
20 PRESSURE
RESSURE
REDUCING
EST PORT
VALVE
19 26 BUCKET SECTION
REGULATED
PRESSURE
TEST
PORT
M
N
UMU- 27 AUXILIARY SECTION
R
32 INLET SECTION
24 PILOT CONTROL
21 PIN/AXLE
DISCONNECT
VALVE
TM2075 (03MAR05)
9025-15-6 - B
30 RIDE CONTROL
VALVE
29 RIDE CONTROL
ACCUMULATOR
28 AUXILIARY
FUNCTION
PILOT
CONTROL 1 LOW PRESSURE OIL
2 LOAD PRESSURE SENSE OIL
3 REGULATED PRESSURE OIL
4 TRAPPED OIL
5 RETURN OIL
Hydraulic System Schematic—Neutral (S.N. 590068—)
TX,9025,HH184 –19–29NOV04–5/5
9025-15-6 644J and 724J Loader

092005
PN=762
9025-15-6 - C
9025-15-6 - Blank
9025
15
7

092005
PN=763
Hydraulic System Component Location

T159050 –19–24SEP02
Loader Hydraulic System (S.N. —590067)

CED,TX04577,845 –19–06NOV03–1/6

092005
PN=764
9025-15-8 - A 9025-15-8 - B
Hydrauli
T159050 –19–2
TM2075 (03
9025-15-8 - A
raulic System Component Location

–19–24SEP02
Loader Hydraulic System (S.N. —590067)

CED,TX04577,845 –19–06NOV03–1/6
5 (03MAR05) 9025-15-8 644J and 724J Loader

092005
PN=764
9025-15-8 - B
1—Hydraulic Reservoir Filter 7—Main Hydraulic Pump 13—Axle Disconnect 20—Pressure Reducing Valve
Vent 8—Hydraulic Return Filter 14—Boom Cylinders 21—Return Tube
2—Hydraulic Oil Cooler 9—Axle and Pin Disconnect 15—Pin Disconnect Cylinder 22—Hydraulic Reservoir
3—Transmission Oil Cooler Valve 16—Bucket Cylinder 23—Regulated Pressure
4—Fan Motor 10—To Steering Valve 17—Ride Control Valve 24—Pump Pressure
5—Fan Pump 11—Ride Control Accumulator 18—Two Lever Pilot Controller 25—Auxiliary Dual Function
6—Hydraulic Pump Control 12—Loader Control Valve 19—Joystick Pilot Controller Pilot Controller
Assembly
Continued on next page CED,TX04577,845 –19–06NOV03–2/6
9025
15
9

092005
PN=765
T121006 –19–07APR99
Brakes & Steering Hydraulic System (S.N. —590067)

092005
PN=766
9025-15-10 - A 9025-15-10 - B
T121006 –19–0
TM2075 (03
9025-15-10 - A
–19–07APR99
Brakes & Steering Hydraulic System (S.N. —590067)
5 (03MAR05) 9025-15-10 644J and 724J Loader

092005
PN=766
9025-15-10 - B
9025
15
11

092005
PN=767
T196144 –19–12DEC03
Loader Hydraulic System (S.N. 590068— )

092005
PN=768
9025-15-12 - A 9025-15-12 - B
T196144 –19–1
TM2075 (03
9025-15-12 - A
–19–12DEC03
Loader Hydraulic System (S.N. 590068— )
5 (03MAR05) 9025-15-12 644J and 724J Loader

092005
PN=768
9025-15-12 - B
1—Hydraulic Reservoir Filter 8—Hydraulic Return Filter 16—Bucket Cylinder 23—Regulated Pressure to
Vent 9—Axle and Pin Disconnect 17—Ride Control Valve Pilot Controls
2—Hydraulic Oil Cooler Valve 18—Two Lever Pilot Controller 24—Pump-to-Pressure
3—Transmission Oil Cooler 10—To Steering Valve 19—Joystick Pilot Controller Reducing Manifold
4—Fan Motor 11—Ride Control Accumulator 20—Pressure Reducing Hydraulic Hose
5—Fan Pump 12—Loader Control Valve Manifold 25—Auxiliary Dual Function
6—Hydraulic Pump Control 13—Axle Disconnect 21—Return Tube Pilot Controller
Assembly 14—Boom Cylinders 22—Hydraulic Reservoir 26—Boom Down Accumulator
7—Main Hydraulic Pump 15—Pin Disconnect Cylinder
9025
15
13

092005
PN=769
T196145 –19–15DEC03
Brakes & Steering Hydraulic System (S.N. 590068— )
CED,TX04577,845 –19–06NOV03–6/6

092005
PN=770
9025-15-14 - A 9025-15-14 - B
T196145 –19–1
TM2075 (03
9025-15-14 - A
–19–15DEC03
Brakes & Steering Hydraulic System (S.N. 590068— )
CED,TX04577,845 –19–06NOV03–6/6
5 (03MAR05) 9025-15-14 644J and 724J Loader

092005
PN=770
9025-15-14 - B
Diagnose Hydraulic System Malfunctions
No Hydraulic Functions Pilot enable switch off Turn switch on.
Pilot enable switch failed Perform pilot controller lock check.

See Complete Machine Operational
Stuck open relief valve Replace relief valve.
Improper Pilot Pressure See Pressure Reducing Valve

Continued on next page TX,15,SS3744 –19–30SEP03–1/11
9025
15
15

092005
PN=771
Slow Hydraulic Functions Cold oil See Hydraulic Oil Warm-Up

Slow engine speed See Diagnose Engine Malfunctions.

(Group 9010-15.)
Suction line air leak Check for foamy oil. (Operator’s

Manual.)
Low oil supply Add recommended oil. (Operator’s

Manual.)
Wrong oil viscosity Use recommended oil. (Operator’s

Manual.)
Relief valve See Loader System Relief and

Circuit Relief Valve Pressure Test in
this group.
Oil leaking past cylinders or control See Loader Cylinder Drift Test.
valve (Group 9025-25.)
Pump regulator out of adjustment See Pump Load Sense Differential

and Standby Pressure Test. (Group
9025-25).
Blocked or damaged line Inspect lines.
Faulty or misadjusted pressure See Pressure Reducing Valve

reducing valve Pressure Test. (Group 9025-25.)
9025
15 Faulty pilot control valve See Pressure Reducing Valve
16
Binding loader control valve spool Inspect valve.
Leaking secondary steering See Secondary Steering Manifold

secondary check valve Secondary Check Valve Leakage
Leaking steering valve See Steering Valve Leakage Test.

(Group 9025-25.)

092005
PN=772
Noisy Hydraulic Pumps Low oil supply or wrong viscosity Fill reservoir with recommended oil.
Plugged or pinched suction line Clean or replace line.
Air in oil Check for foamy oil. Tighten

connections. Replace O-rings and/or
lines.
Loose or missing hydraulic line Tighten or replace clamps.

clamps
Hydraulic lines in contact with frame Inspect and repair.
Worn or damaged pump Hydraulic Pump Flow Test. (Group

9025-25.)
No Steering Functions Frame locking bar in place Pin locking bar in unused position.
Low oil level Add oil. See Drain and Refill

Capacities—724J (S.N. —590067) or
see Drain and Refill Capacities (S.N.
590068— ).(Operator’s Manual.)
No load sense signal (Secondary Check service codes. See

Steering Only) Diagnostic Trouble Codes Quick
Reference List (S.N. —590067)
(Group 9015A-20) or see Diagnostic
Trouble Codes Quick Reference List
(S.N. 590068— ). (Group 9015B-20.)
Pinched steering line Inspect and repair line. 9025

15
17
Steering valve malfunction See Steering Valve Leakage Test.
(Group 9025-25.)
Hydraulic pump malfunction Remove and inspect return filter for

metal pump particles.
Pump drive malfunction See Hydraulic Pump Flow Test.

(Group 9025-25.) See Hydraulic
Pump Remove and Install. (Group
3160.)

092005
PN=773
Boom Float Function Does Not Return-To-Carry switch on Turn switch off.
Work
Low pilot control pressure See Pressure Reducing Valve

Faulty detent in pilot controller See Chassis Control Unit Circuit

Theory of Operation (S.N. —590067)
(Group 9015A-15) or see Flex Load
Controller (FLC) Circuit Theory of
Operation (S.N. 590068— ). (Group
9015B-15.)
Faulty pilot control valve See Pressure Reducing Valve

Loader control valve spool binding in See Hydraulic Pump Disassemble

bore and Assemble. (Group 3160.)
One Hydraulic Function Does Not Faulty pilot control valve See Pressure Reducing Valve
Work Pressure Test. (Group 9025-25.)
Stuck open circuit relief valve See Relief Valve Disassemble and
Assemble. (Group 3160.)
Anti-cavitation valve open Inspect and repair valve. (Group

3160.)
Oil leaking past cylinder packings See Boom, Bucket and Steering
Cylinder Leakage Test. (Group
9025 9025-25.)
15
18
Blockage in oil lines or valve Inspect lines for damage. Disconnect
and inspect lines for internal
blockage.
Loader control valve spool stuck in See Hydraulic Pump Disassemble

bore and Assemble. (Group 3160.)

092005
PN=774
Low Hydraulic Power Low relief valve setting See Maximum System Pressure
Pump control adjustment See Pump Load Sense Differential

and Standby Pressure Test. (Group
9025-25.)
Low circuit relief valve setting See Loader System Relief and
Circuit Relief Valve Pressure Test.
(Group 9025-25.)
Faulty or misadjusted pressure See Pressure Reducing Valve

reducing valve Pressure Test. (Group 9025-25.)
Leaking relief valve Remove and inspect valve. (Group

3160.)
Worn hydraulic pump Hydraulic Pump Flow Test. (Group

9025-25.)
Faulty pilot control valve See Pressure Reducing Valve

Function Drifts Down Leaking cylinders Cap off boom cylinder to isolate if
leakage is in cylinder or in circuit
before doing Loader Cylinder Drift
Leaking seals in circuit relief valve or Inspect relief valve seals.

valve stuck open
9025
Leakage in ride control circuit. Perform ride control check. See 15
19
Complete Machine Operational
Faulty boom down accumulator See Electrical Component

solenoid. Specifications (S.N. —590067)
(Group 9015A-20) or See Electrical
Component Specifications (S.N.
590068— ). (Group 9015B-20.)
Leaking loader control valve Loader Control Valve Disassemble

and Assemble. (Group 3160.)
Boom Drifts Up Check valve leakage Inspect check valve. (Group 3160.)

092005
PN=775
Boom Down Does Not Work Boom down button not pushed Push button.
(Engine Off)
Pilot enable switch off Push switch on.
Boom down accumulator solenoid Check solenoid resistance. See

malfunction Electrical Component Specifications
(S.N. —590067) (Group 9015A-20)
or See Electrical Component
(Group 9015B-20.)
Pilot enable solenoid malfunction Check solenoid resistance. See

(S.N. —590067) (Group 9015A-20)
or See Electrical Component
(Group 9015B-20.)
Improper pilot accumulator See Boom Down Accumulator

precharge. Precharge Test. (Group 9025-25.)
9025
15
20

092005
PN=776
Oil Overheats Low oil viscosity in hot weather Replace with correct oil. See Drain
and Refill Capacities—724J (S.N. —
590067) or see Drain and Refill
Capacities (S.N. 590068—
).(Operator’s Manual.)
Cooler by-pass stuck open Inspect and repair cooler bypass.

(Group 3160.)
Plugged fins in oil cooler Inspect and clean oil cooler.
Missing turbulaters inside oil cooler Replace oil cooler. See Radiator, Oil,
And Air Cooler Remove and Install.
(Group 3160.)
Incorrect relief or circuit relief valve See Loader System Relief and
setting Circuit Relief Valve Pressure Test
(Group 9025-25.)
Restriction in oil lines or loader valve Inspect for dented or kinked lines.
Leaking relief valve Remove and inspect valve and

seals. (Group 3160.)
Worn hydraulic pump (internal See Hydraulic Pump Flow Test.

leakage) (Group 9025-25.)
Hydraulic Oil Foams Low oil level Add oil. See Drain and Refill
590068— ). (Operator’s Manual.) 9025
15
21
Wrong oil Replace with correct oil. See Drain
and Refill Capacities—724J (S.N. —
590067) or see Drain and Refill
Capacities (S.N. 590068— ).
Water in oil Change oil. See Drain and Refill

590068— ). (Operator’s Manual.)
Loose or faulty suction lines (air leak Tighten or install new lines.
in system)

092005
PN=777
Pin Disconnect Cylinders Will Electrical circuit failure Hold a screwdriver against end of
Not Retract pin disconnect solenoid valve and
check for magnetism with switch
pushed. See Section 9015A or
9015B if problem is electrical.
Solenoid valve failure Remove and inspect.
Cylinder binding Inspect cylinder and adjust loads.
Constant Steering To Maintain Air in system Check for foamy oil.

Straight Travel
Leaking cylinder packings See Boom, Bucket and Steering

Cylinder Leakage Test. (Group
9025-25.)
Worn steering valve See Steering Valve Leakage Test.

(Group 9025-25.)
Cylinder pin or bore wear Inspect and repair pins.
Slow Steering Wheel Movement Worn steering valve gerotor See Steering Valve Leakage Test.
Will Not Cause Any Frame (Group 9025-25.)
Movement
Steering Wheel Turns With No Broken steering column or splined Remove and inspect steering
Resistance and Causes No coupling column.
Frame Movement
9025 Lack of oil in steering valve Start engine and check steering
15 operation.
22
Sticking steering inlet manifold Remove and inspect primary

primary check valve (machines with manifold check. Replace secondary
secondary steering only) steering inlet manifold if necessary.
Steering valve malfunction See Steering Valve Remove and


092005
PN=778
Erratic Steering Air in oil Check for foamy oil.

Loose cylinder piston Remove rod and inspect piston. See

Steering Cylinder Remove and
Damaged steering valve See Steering Valve Remove and

Spongy or Soft Steering Air in oil Check for foamy oil.

Free Play at Steering Wheel Loose steering wheel nut Tighten steering wheel nut.
Worn or damaged splines on Remove steering valve and inspect

steering column or valve spline.
Steering Valve Binding or Binding in steering column or Remove steering valve and inspect
Steering Wheel Does Not misalignment of column spline.
Immediately Return to Neutral
When Released
9025
High return pressure Check for a pinched or damaged 15
23
return line.
Contamination in steering valve Inspect hydraulic filter for

contamination. Repair cause of
contamination. Flush hydraulic
system.

092005
PN=779
Steering Valve Locks Up Large particles of contamination in See Hydraulic Oil Filter Inspection
steering valve Procedure. (Group 9025-25). If
repair is cause of contamination,
flush hydraulic system. See
Hydraulic Oil Clean-Up Procedure
Using Portable Filter Caddy. (Group
9025-20.)
Worn or damaged steering valve See Steering Valve Remove and

Steering Wheel Turns By Itself Lines connected to wrong port Reconnect lines. See Hydraulic
System Component Location in this
group.
Machine Turns in Opposite Lines to cylinders connected to Connect lines to correct ports. See
Direction wrong ports at steering valve. Hydraulic System Component
Location in this group.
Machine Turns When Steering Leakage in steering valve See Steering Valve Leakage Test.
Valve is in Neutral (Group 9025-25.)
Steering Wheel Kickback Failed check valve in secondary On machines without secondary
steering manifold block steering and both steering and
loader functions are held over relief
at the same time and then loader
lever is released, steering wheel
kickback is normal. On machines
with secondary steering, a failed
check valve is indicated. See
9025 Secondary Steering Manifold
15 Secondary Check Valve Leakage
24
Jerky Steering Hydraulic Fluid Contamination Run hydraulic fluid through filter
caddy.
Load sense differential pressure not See Pump Load Sense Differential
adjusted properly. and Standby Pressure Test. (Group
9025-25.)

092005
PN=780
Secondary Steering Motor Will Electrical malfunction. See Complete Machine Operational
Not Run Checkout. (Group 9005-10.)
Seized pump See Hydraulic Pump Disassemble

and Assemble. (Group 3160.)
Secondary Steering Pump Runs Stuck open secondary steering See Secondary Steering Manifold
But Will Not Steer Machine manifold block primary check valve Primary Check Valve Leakage Test.
(Group 9025-25.)
TX,15,SS3744 –19–30SEP03–11/11
9025
15
25

092005
PN=781
9025
15
26

092005
PN=782
Group 20
Adjustments
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy
ESSENTIAL TOOLS 3. To minimize oil loss, pull a vacuum in reservoir

JT05746 Portable Filter Caddy using a vacuum pump. Connect filter caddy suction
JT05750 Discharge Wand line to drain port at bottom of reservoir using
connector and quick disconnect fitting. Check to be
SERVICE EQUIPMENT AND TOOLS sure debris has not closed drain port.
Quick Disconnect Fittings
4. Put filter caddy discharge wand into reservoir filler
JT03297 Connector (1-1/16 M ORB x 3/4 M NPT)
hole so end is as far away from drain port as
Two Hoses 3658 mm (12 ft) x 3/4 in. I.D. 100R1 with 3/4 M NPT
possible to clean bottom of reservoir.
Ends
Adapter Hoses
5. With engine off, start the filter caddy. Check to be
JT05510 Vacuum Pump sure oil is flowing through the filters.
IMPORTANT: Brake system uses oil from Operate filter caddy approximately 15 minutes.
hydraulic reservoir. Flush all lines in
the brake, pilot, differential lock, and Leave filter caddy operating for the next steps.
clutch cut-off system. Disassemble
and clean pressure reducing valve 6. Start the engine and run it at fast idle.
and pilot controller. Remove and
clean pilot caps from main control IMPORTANT: For the most effective results,
valve. Brake components may fail if cleaning procedure must start with
brake system is not cleaned after the smallest capacity circuit then
hydraulic reservoir contamination. proceed to the next largest capacity
circuit.
1. If hydraulic system is contaminated due to a major
component failure, remove and disassemble 7. Operate all functions, one at a time, through a
steering cylinders to clean debris from cylinders. complete cycle in the following order: auxiliary
equipment, steering, bucket and boom.
2. Install new return filter element.
Repeat operation for approximately 30 minutes.
IMPORTANT: To prevent cavitation of filter caddy Continue procedure for at least 10 more minutes if 9025
pump, the minimum I.D. of connector machine has auxiliary equipment. 20
1
is 1/2 in.
8. Stop the engine. Remove the filter caddy.
NOTE: For a failure that creates a lot of debris,
remove access cover from reservoir. Drain 9. Install new return filters.
reservoir and connect filter caddy suction line
to drain port. Add a minimum of 19 L (5 gal) of 10. Check oil level in reservoir. Add oil if necessary.
oil to reservoir. Operate filter caddy and wash See Drain and Refill Capacities. (Operator’s
out the reservoir. Manual.)
CED,TX13067,40 –19–05AUG96–1/1

092005
PN=783
Adjustments
Return-To-Dig Adjustment
To adjust return-to-dig setting, see Return-to-Dig

Adjustment (S.N. —590067) (Group 9015A-20) or see
Return-to-Dig Adjustment (S.N. 590068— ). (Group
9015B-20.)
DW09104,00000A9 –19–22SEP03–1/1
Return-To-Carry and Boom Height Kickout

Adjustment
To adjust return-to-carry or boom height kickout setting,

see Return-to-Carry Kickout Adjustment (S.N. —590067)
(Group 9015A-20), See Boom Height Kickout Adjustment
(S.N. —590067) (Group 9015A-20), or see BHKO/RTC
Adjustment (S.N. 590068— ). (Group 9015B-20.)
DW09104,00000A8 –19–22SEP03–1/1
Pump Load Sense Differential and Standby

Pressure Adjustment
9025 To adjust pump load sense differential or standby

20 pressure, see Pump Load Sense Differential and Standby
2 Pressure Test. (Group 9025-25.)
DW09104,000009F –19–21AUG03–1/1
Pilot Controller Adjustment—Two Lever Pilot
1. Turn engine off.
2. Slide boot up and over pilot control lever.
Continued on next page LS10960,0000026 –19–02OCT03–1/2

092005
PN=784
Adjustments
3. Turn adjustment screw (2) up to lock nut (1).
4. Turn out adjustment screw equal number of turns until

contact is made with push pin (3).
NOTE: Hydraulic functions will be limited if both pilot
–UN–04SEP02
control levers are not vertical after adjustment.
5. Check adjustment. Lever must be vertical with no loose

movement.
T159121B
6. When adjustment is complete, slide boot down over
pilot control levers.
1—Lock Nut (4 used)
2—Adjustment Screw (4 used)
3—Push Pin (4 used)
LS10960,0000026 –19–02OCT03–2/2
Ride Control Accumulator Hydraulic

Discharge
CAUTION: Prevent possible injury from high

pressure fluid. Discharge accumulator before
servicing any ride control components.
Hydraulic oil in accumulator can be stored at
pressures equal to or above system relief
pressures.
This test will ensure that no hydraulic pressure remains in 9025

20
ride control accumulator prior to charging accumulator.
3
1. Perform Hydraulic Oil Warm-Up Procedure in this

group.
2. Lower boom and bucket to ground and stop engine.

092005
PN=785
Adjustments
3. Install JT02156A Digital Pressure Analyzer with 5000

psi pressure transducers to ride control quick coupler
(2).Perform Digital Pressure And Temperature Analyzer
Installation procedure. (Group 9025-25.)
–UN–27JAN03
CAUTION: Prevent possible injury from moving
components. Make sure area around boom and
bucket is clear. Boom may jump upward during
this check.
T164577B
NOTE: With ride control switch in manual position, one
light on Sealed Switch Module (SSM) and Ride Ride Control Valve
Control symbol on monitor will be illuminated.
1—Ride Control Valve
4. Turn key switch to on position. Without starting engine, 2—Quick Coupler
cycle ride control switch to manual position. If boom or
bucket rise, pressure remains in ride control
accumulator.
5. Press and hold pilot enable/boom down switch while

holding the boom control lever in boom down position
until digital pressure gauge reads zero.
DW09104,00000B4 –19–13NOV03–2/2
Charge Ride Control Accumulator
9025 Hydraulic Oil Temperature 60—71°C JT01735 Gas Valve

20 140—160°F
4 Charge Ride Control 2068 ± 138 kPa (20 ± 1 bar)
Accumulator Charge Pressure (300 ± 20 psi)

092005
PN=786
Adjustments
CAUTION: Prevent possible injury from high

pressure fluid. Discharge accumulator before
servicing components. Hydraulic oil in
accumulator can be stored at pressures equal
to or above system relief pressures.
1. Warm hydraulic oil to specification.
Specification
Hydraulic Oil—Temperature ........................................................ 60—71°C
140—160°F
IMPORTANT: Charge accumulator using only dry

nitrogen. Dry nitrogen does not mix
with oil and is non-combustible. It will
not cause oxidation or condensation
inside accumulator and is not harmful
to piston seal. Do not use air or any
combustible gas as these can cause
oxidation and condensation. Oxidation
–UN–10SEP91
and condensation are harmful to piston
seal and accumulator.
NOTE: Ride control can not be discharged if switch is in
T7594AA
automatic position unless machine is moving
above 5 km/h (3 mph), use on position to
discharge accumulator during this procedure.
2. If accumulator is to be charged on machine and has

some nitrogen pressure left with boom raised slightly,
turn ignition switch to on position. Cycle the ride control
switch from off to on. Boom will jump up unexpectedly
if ride control accumulator is energized. Press boom 9025
20
–UN–10SEP91
enable switch, move the control lever into the float
5
position, and hold for 5 seconds.
3. Remove cover and cap from top of accumulator.
T7594AB
4. Turn handle on gas valve fully counterclockwise.
Attach gas valve, hose, and regulator to accumulator. Cross Section Of Gas Valve Fitting
A—Special Nut

092005
PN=787
Adjustments
CAUTION: Prevent possible injury from

pressurized fluid. Do not loosen bottom fitting.
Bottom fitting is accumulator gas valve fitting.
Loose fitting under pressure can cause injury.
5. Loosen special nut (A) (counterclockwise) 2 1/2 turns

to open gas valve in accumulator. (Resistance may be
felt at approximately 1 1/2 turns.)
6. Slowly open regulator valve to pressurize accumulator

to specification.
7. If accumulator is to be charged on machine and has no

nitrogen pressure left. With boom raised slightly, turn
ignition switch to on position. Cycle the ride control
switch from off to on. Boom will jump up unexpectedly
if ride control accumulator is energized. Press boom
enable switch and move the control lever into the float
position and hold for 5 seconds.
8. Check that accumulator is pressurized to

specifications. Adjust regulator as required.
Specification
Charge Ride Control
Accumulator—Charge Pressure ....................................... 2068 ± 138 kPa
20 ± 1 bar
300 ± 20 psi
9. Tighten nut until snug to close gas valve.
10. Close the valve handle on the nitrogen tank.

9025
20 11. Slowly loosen the connector at pressure regulator
6 valve to release pressure from hose.
12. Remove gas valve from accumulator. Install cap.
CED,TX13067,61 –19–22SEP03–3/3

092005
PN=788
Adjustments
Auxiliary Valve Section—Stroke Adjustment
NOTE: The auxiliary sections (3rd and 4th) of the loader

control valve are equipped with spool stroke
adjusters in each end cap. The adjusters allow the
maximum auxiliary section flow to be set
–UN–13APR99
anywhere from a few gallons per minute (gpm) to
full pump flow. This is done by limiting spool travel
in the valve section and in turn limiting flow. They
are set at full flow at the factory.
T121154
1. Release hydraulic oil pressure from system.
2. Install flow meter in implement circuit to be tested to A—End Cap

B—Cartridge
check flow.
C—Hex Nut
D—Set Screw
3. Perform Hydraulic Oil Warm-Up Procedure. (Group E—Cap Screw
9025-25.) F—Auxiliary Valve Section
4. Loosen hex nut (C) and adjust set screw (D) in the end
cap of the auxiliary valve section of main control valve.
Adjust flow to specification for implement desired.
CED,TX04577,847 –19–02OCT03–1/1
9025
20
7

092005
PN=789
Adjustments
9025
20
8

092005
PN=790
Group 25
Test
Hydraulic Oil Warm-Up Procedure
NOTE: SERVICE ADVISOR™ system, Monitor Display Menu—Diagnostics—Hydraulic. (Operator’s

Unit (MDU) (S.N. —590067), or CAN Monitor Manual.)
Unit (CMU) (S.N. 590068— ) can be used to
display hydraulic oil temperature. Temperature 2. Operate engine at fast idle with park brake switch in
sensor is located in the return oil manifold tube OFF position.
on the reservoir.
3. Hold bucket curl function over relief and raise and
1. (S.N. —590067) Display hydraulic oil temperature lower boom.
using Monitor Display Unit (MDU).
4. Periodically cycle all hydraulic functions to distribute
• Press MENU to get Diagnostic Mode (d) warm oil.
displayed and start engine.
• Press SELECT to get (d 01) displayed, then 5. Heat hydraulic oil to specification.
press NEXT until (d 06) is displayed.
• Press SELECT to get d 061 displayed to activate Specification
hydraulic system oil temperature. Hydraulic Oil—Temperature ................................................. 60—71°C
140—160°F
(S.N. 590068— ) Display hydraulic oil temperature

6. Press MENU once to return to home screen.
using CMU. See Monitor Display Unit—Main
SERVICE ADVISOR is a trademark of Deere & Company DW09104,00000B5 –19–13NOV03–1/1
Digital Pressure And Temperature Analyzer

Installation
Service Equipment And Tools 9025
JT02156A Digital Pressure and Temperature Analyzer 1
–UN–25AUG95
Use the digital pressure and temperature analyzer in
place of analog gauges and a separate temperature
reader.
T8543AI
Transducers (B) are temperature sensitive. Allow
JT02156A Digital Pressure And Temperature Analyzer
transducer to warm to system temperature. After
transducer is warmed and no pressure applied, push A—Digital Pressure and Temperature Analyzer
sensor zero button for 1 second to set the true zero point. B—3400 kPa (35 bar) (500 psi) Transducer
34 000 kPa (350 bar) (5000 psi) Transducer
When using for different pressures, turn selector to OFF 70 000 kPa (700 bar) (10 000 psi) Transducer
for 2 seconds and then to the pressure range. Readings
are inaccurate if proper range for transducer is not used.
DW09104,0000078 –19–10SEP02–1/1

092005
PN=791
Test
Fan Pump Pressure Test
IMPORTANT: Unplug solenoid on back side of fan ESSENTIAL TOOLS

motor before running test. 38H1031 (—8 M x —8 F x —8 M ORFS) Tee
JT03457 (7/16—20 M x —8 F ORFS) Adaptor
SPECIFICATIONS
Oil Temperature 65 ± 6°C (150 ± 10°F) SERVICE EQUIPMENT AND TOOLS
Fan Pump Pressure 20 000 kPa (200 bar) (3000 psi) Gauge
Engine Speed—Fast Idle 18443—19133 kPa (184—191
Pressure bar) 2675—2775 psi)
Engine Speed—Slow Idle 1999 kPa (20 bar) (290 psi)
Pressure (Minimum)
9025
25
2

092005
PN=792
Test
NOTE: This test checks the hydraulic fan pump output

pressure. This can also be accomplished by doing
the Fan Motor rpm Test. The fan motor rpm
method checks pump pressure by checking Fan
Motor rpm. This is the preferred test if a digital
hand held tachometer (JT05719) is available. See
–UN–24FEB98
Fan Motor Speed Test in this Group.
1. Install frame locking bar.
T113746B
2. Make test connections as shown with tee (A), adapter
(B) at fan pump outlet using existing hose (C). Pump is
located on left side rear of engine.
A—JT03457 Adaptor (7/16—20 M x —8 F ORFS)
B—38H1031 Tee (—8 M x —8 F x —8 M ORFS)
C—Existing Hose
group.
4. Operate engine at proper specification and record

pressure.
Specification
Fan Pump Pressure—Engine
Speed—Fast Idle—Pressure ..................... 18443—19133 kPa (184—191
bar) (2675—2775 psi)
Engine Speed—Slow Idle—
Pressure ....................................................... 1999 kPa (20 bar) (290 psi)
(Minimum)
If Fan Pump Pressure Is Out Of Specification At Fast

Idle:
IMPORTANT: If relief valve is adjusted DO NOT

Exceed Fast Idle Pressure or Fan Motor 9025
rpm specification. 25
3
• Inspect relief valve in fan motor for contamination or
seal leakage. Replace if necessary.
If Fan Pump Pressure Is Out Of Specification At Slow

& Fast Idle:
• See Fan Pump Flow Test in this Group.

seal leakage. Replace if necessary.
CED,TX04577,519 –19–22OCT02–2/2

092005
PN=793
Test
Fan Motor Speed Test
NOTE: This test can be done in place of the Fan 4. Operate engine at high idle and record rpm.
Pump Pressure Test in this Group. It will help
determine if the relief valve in the motor is 5. Repeat step (4) using Low Speed setting.
working properly or if the pump itself is
defective. 6. Operate engine at high idle and record rpm.
SPECIFICATIONS Specification
Oil Temperature 65 ± 6°C (150 ± 10°F) Oil—Temperature ............................................ 65 ± 6°C (150 ± 10°F)
Fan Motor Speed—High
Cooling System: Speed, Engine Speed—Fast
Fan Motor Speed, Engine 1550 - 1650 rpm Idle—rpm .................................................................. 1550 - 1650 rpm
Speed—High Speed—High Idle Fan Motor Speed—Low Speed,
rpm Engine Speed—Fast Idle—rpm ............................ Less than 800 rpm
Fan Motor Speed, Engine Less than 800 rpm
Speed—Low Speed—High Idle If Fan Speed Is Out Of Specification At Full Speed
rpm Fast Idle:
SERVICE EQUIPMENT AND TOOLS • Replace variable fan speed solenoid.

JT05709 Reflective Tape • Inspect relief valve in fan motor for contamination or
JT05719 Hand Held Digital Tachometer seal leakage. Replace if necessary.
IMPORTANT: If relief valve is adjusted do not

NOTE: This test requires two people to complete. One
exceed fast idle pressure or fan
in operator station and other to hold the digital
motor speed specification.
held tachometer for reading the fan speed.
1. Place piece of reflective tape on fan hub.

If Fan Speed Is Out Of Specification At Low Speed
and Full Speed High Idle:
group.
• See Fan Pump Flow Test in this Group.
3. (S.N. —590067) Set Diagnostic Menu (d064) to
9025 seal leakage. Replace if necessary.
High Speed. See Monitor Display Unit—Diagnostics
25
4 Menu (S.N. —590067). (Group 9015A-15.)
IMPORTANT: If relief valve is adjusted do not
exceed fast idle pressure or fan
(S.N. 590068— ) Set fan speed to 100% by
motor speed specification.
accessing Machine Config under Main Menu in the
CAN Monitor Unit (CMU). See CAN Monitor Unit
(CMU) Circuit Theory of Operation (S.N. 590068—
). (Group 9015B-15.)
CED,TX04577,520 –19–22OCT02–1/1

092005
PN=794
Test
Fan Pump Flow Test
SPECIFICATIONS
Oil Temperature 65 ± 6°C (150 ± 10°F)
Engine Speed Fast Idle
Test Pressure 16616 kPa (166 bar) (2410 psi)
Cooling System: New Pump Flow 56.8 L/min (15 gpm)
(Minimum)
Used Pump Flow (Minimum) 53.0 L/min (14.0 gpm)
ESSENTIAL TOOLS
—8 F ORFS Ends —8 Test Hose

JT07148 Flow Meter
This test will determine if pump outlet flow is within proper

specification.
9025
25
5

092005
PN=795
Test
–UN–12SEP97
T111175
A—Existing Hose B—Test Hose
NOTE: This test is recommended only after the Fan 4. Perform Hydraulic Oil Warm-Up Procedure in this
Pump Pressure Test or Fan Motor Speed Test group.
in this Group has been done and failed to
9025 meet specification. 5. Operate engine at proper specification and record
25 pump flow.
6
Specification
2. Make test connections as shown using existing Engine—Speed ...................................................................... Fast Idle
Test—Pressure ................................. 16616 kPa (166 bar) (2410 psi)
hose (A) to flow meter and test hose (B) at fan Cooling System New—Pump
pump outlet. Pump is located on left side rear of Flow (Minimum) ............................................... 56.8 L/min (15.0 gpm)
engine. Used—Pump Flow (Minimum)......................... 53.0 L/min (14.0 gpm)
3. Use the monitor or SERVICE ADVISOR™ system to If Pump Flow Is Low:

read engine rpm and hydraulic oil temperature. See
Monitor Display Unit—Diagnostics Menu or • Disassemble and inspect pump.
SERVICE ADVISOR system template. See
SERVICE ADVISOR System Computer Connection If Pump Flow Is Ok:
for information on connecting to J-Series loaders
(S.N. —590067). • Do Fan Motor Case Drain Test in this Group.
SERVICE ADVISOR is a trademark of Deere & Company CED,TX04577,521 –19–22OCT02–2/2

092005
PN=796
Test
Fan Motor Case Drain Test
NOTE: This test determines if case drain leakage is

within specification.
SPECIFICATIONS
Engine Speed Slow Idle
Case Drain Leakage (maximum) 75 mL (2.5 oz) per minute
ESSENTIAL TOOLS
38H1415 Cap (—6 F ORFS)

Vacuum Pump
Measured Container Approximately Pint
9025
25
7

092005
PN=797
Test
–UN–11NOV03
T196165
A—Cap B—Hydraulic Reservoir
Breather Filter
2. Remove hydraulic reservoir breather filter (B). Specification

Engine—Speed ...................................................................... Slow Idle
Connect vacuum pump to the reservoir breather
Case Drain—Leakage
9025 filter adapter (3/4 - 16 UNF male thread). (maximum) ................................................. 75 mL (2.5 oz) per minute
25
8 3. Remove case drain hose going to reservoir If Case Drain Flow Is High:
manifold. Cap port on return manifold with (A),
located under right side of cab. • Disassemble and inspect fan motor.
4. Place hose in container approximately 475 mL If Case Drain Flow Is OK:
(16oz).
• Inspect relief valve for contamination or seal
5. Perform Hydraulic Oil Warm-Up Procedure in this leakage. Replace if necessary.
group.
6. Operate engine at proper specification and record

case drain flow.
CED,TX04577,522 –19–22OCT02–2/2

092005
PN=798
Test
Pump Load Sense Differential And Standby Pressure Test
SPECIFICATIONS differential pressure is the difference

Hydraulic Differential Pressure 1759—1965 kPa between pump output and load
17.62—19.62 bar sense pressures, use Digital
255—285 psi
Pressure Temperature Analyzer
Low Standby Pressure 4654—4998 kPa (JT02156A). Do not use two separate
46.5—49.9 bar
gauges.
675—725 psi
NOTE: This test should be performed with bucket

installed on loader boom to help increase
system pressure when adjusting differential
and standby pressure to specification.
IMPORTANT: This test consists of two
adjustments. The differential 1. Perform Hydraulic Oil Warm-Up Procedure in this
pressure must be adjusted first group.
because a differential pressure
adjustment will also affect the low 2. Stop engine.
standby pressure setting. Since
9025
25
9

092005
PN=799
Test

psi pressure transducers to pump outlet pressure test
port (E) (S.N. —590067) or (5) (S.N. 590068— ) and
load sense pressure test port (C). Perform Digital
Pressure And Temperature Analyzer Installation
procedure. (Group 9025-25.)
E—Pump Outlet Pressure Test Port
–UN–26AUG96
T103264B
Pump Outlet Pressure Test Port (S.N. —590067)
9025
25
10

092005
PN=800
Test
1—Pressure Reducing Manifold

2—Regulated Pressure Test Port
3—Pressure Reducing Adjustment Screw
4—Pressure Reducing Adjustment Locknut
5—Pump Outlet Pressure Test Port
–UN–10DEC03
T196177A
Pressure Reducing Valve (S.N. 590068— )
9025
25
11

092005
PN=801
Test
NOTE: (S.N. —590067) Raise boom as slowly as

possible to get this pressure.
(S.N. 590068— ) Boom operation not necessary

on later machines.
–UN–17FEB97
5. With engine at slow idle, raise boom as slowly as
possible.
6. Record differential pressure reading. Pressure must be
T107095B
Specification Hydraulic Pump Control Relief Valve Adjustments

Hydraulic Differential—Pressure ..................................... 1759—1965 kPa
17.62—19.62 bar A—Load Sense Valve—Differential Pressure
255—285 psi B—Relief Valve—Low Standby Pressure
C—Load Sense Pressure Test Port
7. If pressure is not within specification, adjust load sense
valve (A) in to increase and out to decrease pressure.
8. Cycle hydraulic function to ensure valve spools are

seated properly and verify differential pressure.
9. With engine at slow idle and differential pressure within

specification, record standby pressure at pump outlet
pressure test port (E) (S.N.—590067) or (5) (S.N.
590068— ) . Pressure must be within specification.
Specification
Low Standby—Pressure .................................................. 4654—4998 kPa
46.5—49.9 bar
675—725 psi
9025 10. If pressure is not within specification, adjust relief

25 valve (B) on pump control valve. If adjustment is
12 made, cycle hydraulic function to ensure valve spools
are seated properly and verify pressure.
CED,TX04577,523 –19–07NOV03–4/4
Maximum System Pressure Test

group.

092005
PN=802
Test

psi pressure transducers to pump outlet pressure test
port (E) (S.N. —590067) or (5) (S.N. 590068— ).
Perform Digital Pressure And Temperature Analyzer
Installation procedure. (Group 9025-25.)
E—Pump Outlet Pressure Test Port
–UN–26AUG96
T103264B
Pump Outlet Pressure Test Port (S.N. —590067)
9025
25
13

092005
PN=803
Test
NOTE: There should be little or no load on the engine

while raising boom. If engine is loading, loader
relief valve maybe leaking or relieving. See
Loader Relief Valve Test in this group.
3. Operate engine at slow idle and hold boom raise

function over relief.
4. Record maximum system pressure reading. Pressure

must be within specification.
Specification
Maximum System—Pressure .................................... 24 476—25 166 kPa
24.4—25.2 bar
–UN–10DEC03
3550—3650 psi

T196177A
CED,TX04577,524 –19–07NOV03–3/4
5. If pressure is not within specification, adjust load sense

relief valve (A) in to increase and out to decrease
pressure.
9025
25 6. If adjustment is made, cycle hydraulic function to
14 ensure valve spools are seated properly and verify
–UN–17FEB97
pressure.
A—Load Sense Relief Valve—Maximum System
T107168B
Pressure
CED,TX04577,524 –19–07NOV03–4/4

092005
PN=804
Test
Hydraulic Pump Flow Test
SPECIFICATIONS
Test Pressure 13,790 kPa (138 bar) (2000 psi)
724J Minimum New Pump: Flow 208 L/min (55 gpm)
Rate
724J Minimum Used Pump: Flow 185 L/min (49 gpm)
Rate
ESSENTIAL TOOLS
38H1419 (—16 F ORFS) (2 used) Cap
38H1150 (—16 M ORFS) Plug
38H1475 (—16 F x —8 M ORFS) Reducer
38H1481 (—8 F x —6 M ORFS) Reducer
38H1002 (—16 M x —16 M x —16 F ORFS) Tee
38H1415 (—6 F ORFS) Cap
38H1420 (—20 F ORFS) Cap

JT07148 Flow Meter
9025
25
15

092005
PN=805
Test
–UN–11NOV03
T196167
A—38H1419 Cap (—16 F C—38H1475 Reducer (—16 F E—38H1002 Tee (—16 M x — F—38H1415 Cap (—6 F ORFS)
ORFS) (2 used) x —8 M ORFS) 16 M x —16 F ORFS) G—38H1420 cap —20 F ORFS)
B—38H1150 Plug (—16 M D—38H1481 Reducer (—8 F
ORFS) x —6 M ORFS)
9025
IMPORTANT: For the test, the flow meter is 2. Heat hydraulic oil to specifications by restricting
25 connected directly to the pump. flow through flow meter. Operate engine at a
16 Since the load sensing relief valve is constant mid-range speed. DO NOT increase speed
located in the loader control valve when flow meter is restricting flow.
and not in this test circuit, there is
no high pressure protection. 3. Open flow meter control valve. Operate engine at
Therefore it is extremely important specified speed.
that the flow meter control valve be
left open at all times, except during Specification
the warm-up and test procedure. Engine—Speed ............................................................ 2000 ± 25 rpm
1. Make test connections. 4. Slowly close the flow meter control valve until the
specified pressure is indicated. Verify engine speed
Install tee and reducers (C, D and E) at the flow and take the flow reading.
meter inlet.
Specification
Test—Pressure ....................................... 13 790 kPa (138 bar) (2000
Disconnect and cap (A, F and G) inlet, return and psi)
load sense-to-pump hoses at the loader control
valve and connect to flow meter.

092005
PN=806
Test
Specification to the steering valve at the pump outlet tee (B).

724J Minimum New Pump:—
Cap or plug hose and steering valve.
Flow Rate............................................................. 208 L/min (55 gpm)
724J Minimum Used Pump:—
Flow Rate............................................................. 185 L/min (49 gpm) 6. Rerun pump flow test. If flow is below specifications
replace pump.
5. If flow is below specifications check hydraulic
reservoir suction hose for restriction. If hose is not 7. If pump is replaced, see See Pump Load Sense
restricted, check steering system leakage before Differential And Standby Pressure Adjustment Test
replacing pump by disconnecting the pressure hose before returning machine to service. (Group
9025-25.)
CED,TX04577,525 –19–28NOV00–3/3
Hydraulic Pump Case Drain Test
NOTE: This test determines the efficiency of the pump

rotating group by measuring the amount of case
drain with the pump at maximum pressure.
Normally this test will help isolate a pump
performance problem to either the rotating group
or the pump control. This test should be
performed before removing the pump for repair.
SPECIFICATIONS
System Pressure Maximum with function bottomed
Case Drain (container) Leakage 15 L (4 gal) in 15 sec.
(Maximum)
Case Drain (Flow Meter) Leakage 60.6 L/min (16 gpm)
(Maximum) 9025
25
Vacuum Pump
Measured Container Approximately 19 L (5 gal) or Flow Meter
38H1150 (—16 Plug ORFS)
JT07148 Flow Meter

group.

092005
PN=807
Test
–UN–11NOV03
T196168
A—Plug—38H1150 (—16 B—Vent Filter—Hydraulic
ORFS) Reservoir
2. Remove vent filter from hydraulic reservoir at (B) 7. Start engine, run at specified speed. As soon as
and connect vacuum pump to vent filter connector there is flow from the case drain hose, hold bucket
9025 to minimize leakage when pump case drain hose is control lever in rollback position.
25 disconnected.
18 Specification
3. If using a measured container, disconnect pump Engine—Speed ............................................................ 2000 ± 25 rpm
case drain hose at pump. Secure the drain hose so
it’s end is higher than the pump to prevent draining 8. Direct oil into the container for 15 seconds, or
the pump case. record flow meter reading.
4. Stop vacuum pump and release vacuum in 9. Measure oil quantity in the container and observe
reservoir. flow meter reading. If above specification, the
rotating group has excessive leakage and the pump
5. Use a measured container to catch the oil flow from must be replaced. Pump cannot be repaired.
the drain hose.
Specification
System—Pressure .................................. Maximum with function held
6. If using a flow meter, install flow meter between over relief
pump case drain hose and reservoir fill inlet. Plug
case drain hose removed from pump with plug (A).

092005
PN=808
Test
Specification
Case Drain (container)—
Leakage (Maximum) ........................................ 15 L (4 gal) in 15 sec.
Case Drain (Flow Meter)—
Leakage (Maximum) ........................................... 60.6 L/min (16 gpm)
CED,TX04577,526 –19–01APR98–3/3
Loader System Relief and Circuit Relief Valve

Pressure Test
Loader System Relief Valve Test
NOTE: The loader system relief valve acts as a clipper

relief valve to protect loader circuit against
hydraulic pressure spikes.
1. Disconnect inlet pressure hose (5) from loader control

valve (4). Cap hose opening.
1—Hydraulic Control Valve—Outlet Port

2—Load Sense Relief
3—Hydraulic Control Valve—Outlet View
4—Hydraulic Control Valve—Inlet View
5—Hydraulic Control Valve—Inlet Port
6—Clipper Relief
9025
25
19
–UN–03SEP03
T194347

092005
PN=809
Test
2. Connect relief valve tester hose to the control valve

inlet.

psi pressure transducers to relief valve tester quick
coupler. Perform Digital Pressure And Temperature
Analyzer Installation procedure. (Group 9025-25.)
4. Run tester until pressure reaches maximum pressure.

If pressure is not within specification, adjust relief valve
(6). Cycle tester several times to ensure that spring
and poppet are properly seated.
644J, 724J—Specification
Maximum System—Pressure .................................... 27 234—28 613 kPa
272—286 bar
3950—4150 psi
–UN–17FEB97
T107354B
9025
25
20

092005
PN=810
Test
Circuit Relief Valve Test
1. With key in on position, operate loader, bucket, or

auxiliary function to relieve pressure in circuit to be
tested.
–UN–17FEB97
2. Disconnect hose for circuit to be tested at cylinder
(bucket dump shown). Install cap (D) on the cylinder
fitting.
T107353B
3. Install union (B) and reducer (A) on loader hose and
connect to tester hose. Install digital pressure
transducer to hose tee.
A—Reducer
B—Union
4. Run tester until pressure reaches maximum pressure.
D—Cap
5. If pressure is not within specification, adjust

appropriate circuit relief valve accordingly. Cycle tester
several times to ensure spring and poppet are properly
seated.
Bucket Rollback, Bucket Curl,
and Auxiliary—Pressure ............................................ 28 613—29 993 kPa
286.1—299.9 bar
4150—4350 psi
Bucket Dump (Tool Carrier)—
Pressure .................................................................... 12 410—13 790 kPa
124.1—137.9 bar
1800—2000 psi
9025
25
21
CED,TX13067,68 –19–15OCT03–3/3

092005
PN=811
Test
Loader Cylinder Drift Test
SPECIFICATIONS
Hydraulic Oil Temperature 60—71°C
140—160°F
Overall Drift Distance 51 mm/min
2.00 in./min
Boom Cylinder Drift Down 2 mm/min
Distance 0.08 in./min
Bucket Cylinder Drift Distance 6 mm/min
0.24 in./min
Boom Cylinder Drift Up Maximum 6 mm in 2 min
Distance (Engine-on) 0.24 in. in 2 min

Temperature Reader
Stop Watch
Dial Indicator
9025
25
22

092005
PN=812
Test
1. Fasten temperature probe to port of cylinder being

tested. Cover probe with a shop towel.

group.
3. Stop engine.
4. To check boom and bucket overall drift rate, measure

drift down at tooth tip (A) for 1 minute using monitor for
time.
Specification
Overall Drift—Distance ............................................................. 51 mm/min
–UN–21OCT88
2.00 in./min
If drift rate is excessive, measure individual cylinder drift

with a dial indicator to determine which circuit is leaking.
T6203AT
Specification
Boom Cylinder Drift Down—
Distance ...................................................................................... 2 mm/min
0.08 in./min
Specification
Bucket Cylinder Drift—Distance ................................................. 6 mm/min
0.24 in./min
5. If drift is excessive for any cylinder, see Boom, Bucket
–UN–26OCT88
and Steering Cylinder Leakage Test (Group 9025-25.)
to determine if leakage is in cylinder or control valve.
NOTE: Boom down solenoid valve leakage can cause
T6222AN
boom to drift up with engine running.
9025
25
Stop engine. Install and zero dial indicator. Start engine. 23
A—Tooth Tip
If cylinder drifts up more than specification, remove

solenoid valve and check seals.
Specification
Boom Cylinder Drift Up—
Maximum Distance (Engine-on) .......................................... 6 mm in 2 min
0.24 in. in 2 min
CED,TX13067,69 –19–22JUN00–2/2

092005
PN=813
Test
Boom, Bucket and Steering Cylinder Leakage

Test
SPECIFICATIONS
140—160°F
–UN–26OCT88
Leakage Test Time 1 minute
Cylinder Leakage Maximum 15 mL/min
1/2 oz/min
T6222AL
ESSENTIAL TOOLS
38H1151 Plug (-20 ORFS) Head End Boom
20 PNLO-S Plug (-20 ORFS) (Parker No. ) Head End Boom
38H1150 Plug (-16 ORFS) Rod End Boom
16 PNLO-S Plug (-16 ORFS) (Parker No. ) Rod End Boom
38H1151 Plug (-20 ORFS) (2 used) Bucket
20 PNLO-S Plug (-20 ORFS) (Parker No.) (2 used) Bucket
1. Fasten temperature sensor to head end port of cylinder

to be tested. Cover sensor with a shop towel.

group.
CAUTION: Avoid possible injury from crushing.

Never work under raised equipment unless
supported with hoist or support stands.
3. Fully extend the cylinder to be tested. If testing the

boom cylinders, restrain boom in the fully raised
9025 position using a hoist or a stand.
25
24 NOTE: Check cylinders for leakage in the fully extended
position only. In the retracted position the piston
contacts the end of the cylinder and seals off
piston seal leakage.
4. Remove and plug cylinder rod end hose or line.
5. Operate engine at slow idle
6. Move control lever to extend cylinder for specified time

while measuring leakage from open port. Use monitor
or Service ADVISOR™ timer.
Specification
Leakage Test—Time .................................................................... 1 minute

092005
PN=814
Test
If leakage is within specification, excessive cylinder drift is

caused by leakage in the loader control valve or circuit
relief valve.
Specification
Cylinder—Leakage Maximum ................................................... 15 mL/min
1/2 oz/min
CED,TX13067,70 –19–22JUN00–2/2
Steering Valve Leakage Test
SPECIFICATIONS
Engine Speed Slow idle
Steering Shaft Torque 11 N•m (97 lb-in.)
Steering Valve Maximum 11.4 L/min. (3 gpm)
Leakage
ESSENTIAL TOOLS
38H1418 (—12 F ORFS) Cap

(approximately 5 gal) Measuring Container
1. Install frame locking bar to prevent machine from

turning.
2. Perform Hydraulic Oil Warm-Up Procedure in this 9025

group. 25
25

092005
PN=815
Test
–UN–11NOV03
T196169
A—38H1418 Cap (—12 F B—Return Hose C—Return Filter
ORFS)
3. If using measured container; Disconnect return Specification

Steering Shaft—Torque ........................................... 11 N•m (97 lb-in.)
hose (B) from loader return filter (C). Install cap (A)
9025 on tee.
25 8. Measure oil flow from return hose for 1 minute.
26 4. If using a flow meter, connect flow meter between
Specification
return hose (B) and tee on return filter. Steering Valve—Maximum
Leakage ............................................................... 11.4 L/min. (3 gpm)
5. Operate engine at specifications.
If leakage is greater than specifications, repair or
Specification replace steering valve. See Remove And Install
Engine—Speed ...................................................................... Slow idle
Steering Valve. (Group 0960.)
6. Quickly turn steering wheel against locking bar to
seat internal check balls in steering valve.
7. Apply specified torque to steering shaft to turn

valve.
TX,25,SS3769 –19–23AUG96–2/2

092005
PN=816
Test
Steering Valve Drift Test
SPECIFICATIONS
140—160°F
Pre-Test Distance 254 mm
10 in
Steering Cylinder Test Pressure 6895 kPa
69 bar
1000 psi
Steering Cylinder Test Time 30 Seconds
Steering Cylinder Maximum Drift 64 mm for one min
2.5 in for one min
ESSENTIAL TOOLS
38H1031 Tee (—8 M x —8 F x —8 M ORFS)
JT03457 Adaptor (7/16—20 M x —8 F ORFS)

Gauge 20 000 kPa (200 bar) (3000 psi)
CED,TX13067,72 –19–23AUG96–1/3
1. Install frame locking bar. Install tee in head end of

steering cylinder and attach gauge. Remove the
locking bar.
9025
2. Perform Hydraulic Oil Warm-Up Procedure in this 25
group. Steer machine back and forth to make sure 27
–UN–17FEB97
steering cylinders contain heated oil.
Specification
Hydraulic Oil—Temperature ........................................................ 60—71°C
T107167B
140—160°F
3. Align machine so bucket corner is against a immovable

object such as a loading dock. Engage park brake. A—Tee
B—Adapter
Continued on next page CED,TX13067,72 –19–23AUG96–2/3

092005
PN=817
Test
4. Adjust steering angle to get specification dimension (A)

on cylinder with gauge on it.
Specification
Pre-Test—Distance ....................................................................... 254 mm
10 in
–UN–21OCT88
5. Display monitor stop watch. See Monitor Display Unit—
Main Menu—Menu Settings—Stopwatch. (Operator’s
Manual.)
T6569AE
NOTE: Do test with hands off of steering wheel. If wheel
rotates move wheel back and forth slightly to
center wheel.
6. Disengage park brake. Put machine in 2nd gear

forward and apply power to maintain specified pressure
reading for specified time.
Specification
Steering Cylinder Test—Pressure ............................................... 6895 kPa
69 bar
1000 psi
Specification
Steering Cylinder Test—Time ................................................. 30 Seconds
7. Measure distance (A) at end of test, subtract from

original setting and compare to specifications.
Specification
Steering Cylinder—Maximum Drift .............................. 64 mm for one min
2.5 in for one min
9025 • If drift is less than specification, steering drift is

25 normal.
28
• If drift is more than specification, see Boom, Bucket
and Steering Cylinder Leakage Test in this group. If
steering cylinder fails leakage test see Steering
Valve Remove and Install. (Group 0960.)
8. Install locking bar and remove test equipment.
CED,TX13067,72 –19–23AUG96–3/3

092005
PN=818
Test
Secondary Steering Pump Relief Valve Pressure Test

Oil Temperature 65 ± 6°C (150 ± 10°F) 0—7000 kPa (0—70 bar) (0—1000 psi) Gauge
Engine Speed 0 rpm
Relief Pressure 5516 ± 344 kPa (55 ± 3.4 bar) 1. Perform Hydraulic Oil Warm-Up Procedure in this
(800 ± 50 psi) group.
ESSENTIAL TOOLS
38H1031 (—8 M x —8 F x —8 M ORFS) Tee
JT03457 (7/16 —20 M x —8 F ORFS) Adapter
Continued on next page TX,25,SS3773 –19–06NOV03–1/2
9025
25
29

092005
PN=819
Test
2. Remove outlet hose (C) coming from secondary

steering pump at elbow.
3. Install tee (A) and adapter (B) to hose and connect to

elbow in pump. Connect pressure gauge.
–UN–24FEB98
IMPORTANT: DO NOT operate secondary steering
pump and motor for more than 15
seconds with the steering in neutral or
damage to the pump and motor can
T113747B
occur.
4. Start engine. Remove engine controller fuse (F6)

(S.N. —590067) or ECU ignition power 5 A fuse (S.N. A—38H1031 Tee (—8 M x —8 F x —8 M ORFS)
B—JT03457 Adapter (7/16 —20 M x —8 F ORFS)
590068— ) . Engine will stop. Secondary steering will
C—Existing Outlet Hose
activate after a short momentary delay. Read pressure D—Adjusting Screw
gauge.
If pressure is not to specification, remove cover (D) and

turn adjusting screw to adjust pressure.
Specification
Engine—Speed ................................................................................. 0 rpm
Relief—Pressure........................................ 5516 ± 344 kPa (55 ± 3.4 bar)
(800 ± 50 psi)
If pressure is low and cannot be adjusted to

specifications:
• See Secondary Steering Valve Primary Check Valve

Leakage Test in this group.
• See Steering Valve Leakage Test in this group.
• Replace secondary steering pump.
9025
25
30
TX,25,SS3773 –19–06NOV03–2/2

092005
PN=820
Test
Secondary Steering Manifold Primary Check

Valve Leakage Test
SPECIFICATIONS
140—160°F
Engine Speed 0 rpm
Secondary Steering Pump 5 ml (0.17 oz)
Leakage per Minute
ESSENTIAL TOOLS
38H1418 Cap (-12 F ORFS)
12 FNL-S Cap (-12 F ORFS) (Parker No.)

Monitor Display Unit
9025
25
31

092005
PN=821
Test
Primary check valve leakage will allow oil to flow from the
secondary steering circuit into the main hydraulic system
during secondary steering operation. This leakage can
cause slow secondary steering.

group.
2. Disconnect line (B) from main hydraulic pump. Install

cap (A) to pump outlet fitting.
IMPORTANT: Do not operate secondary steering

pump and motor for more than 15
seconds with the steering in neutral or
damage to the pump and motor can
occur.
3. Start engine, remove Fuel Shutoff Fuse. Engine will

stop. Secondary steering pump will start.
Specification
–UN–16SEP97
Engine—Speed ................................................................................. 0 rpm
4. Observe leakage from hose (B).
T111323
If leakage is more than specification, replace manifold
block. See Steering Valve Remove and Install. (Group
0960.)
A—38H1418 Cap (-12 F ORFS) (Parker No. 12
FNL-S)
Specification B—Hose from secondary steering pump to
Secondary Steering Pump— steering valve
Leakage per Minute ............................................................. 5 ml (0.17 oz)
9025
25
32
CED,TX13067,74 –19–17SEP93–2/2

092005
PN=822
Test
Secondary Steering Manifold Secondary

Check Valve Leakage Test
SPECIFICATIONS
140—160°F
Secondary Check Valve 5 ml (0.17 oz)
Maximum Leakage, Per Minute
ESSENTIAL TOOLS
38H1147 Plug (—8 M ORFS)
8 PNLO-S Plug (—8 M ORFS) (Parker No. )

Temperature Reader
Secondary check valve leakage will allow oil to flow from

the main hydraulic system to the reservoir through the
secondary steering pump. This leakage can cause slow
cycle times.
–UN–21OCT88
1. Install frame locking bar to prevent machine from
turning.
T6569AJ
group.
A—Secondary Steering Valve Check Valve
3. Remove hose from check valve (A) on secondary B—Plug
steering manifold.
4. Install plug (B) in hose.

9025
5. Operate engine at slow idle. 25
33
6. Observe leakage from check valve (A).
If leakage is more than specification, clean or replace

check valve.
Specification
Secondary Check Valve—
Maximum Leakage, Per Minute ........................................... 5 ml (0.17 oz)
CED,TX13067,75 –19–22JUN00–1/1

092005
PN=823
Test
Pressure Reducing Valve Pressure Test
SPECIFICATIONS
Differential Lock and Pilot Control 4100—4400 kPa
Pressure 41—44 bar
600—650 psi

This procedure is used to test and adjust regulated

pressure in the differential lock and pilot control system.

group.
DW09104,00000A1 –19–22AUG03–1/3
3.
B—Regulated Pressure Test Port
9025
25
34
–UN–07DEC96
T103264D
Continued on next page DW09104,00000A1 –19–22AUG03–2/3

092005
PN=824
Test
Install JT02156A Digital Pressure Analyzer with 5000 psi

pressure transducers to regulated pressure test port (B)
(S.N. —590067) or (2) (S.N.590068— ). Perform Digital
4. Start engine and record pressure. Pressure should be

Specification
Regulated Hydraulic—Pressure ..................................... 4100—4400 kPa
41—44 bar
600—650 psi
5. If pressure is not within specification, loosen pressure
–UN–10DEC03
reducing adjustment locking nut (4) and turn pressure
reducing adjustment screw (3) in to increase and out to
decrease pressure.
T196177A
9025
25
DW09104,00000A1 –19–22AUG03–3/3
35
Cycle Time Test
For machine cycle times, see Complete Machine

Operational Checkout. (Group 9005-10.)
CED,TX13067,32 –19–06OCT03–1/1

092005
PN=825
Test
Brake Accumulator Precharge Test
SPECIFICATIONS
Brake Pressure Indicator Light 2068 kPa
Pressure 21 bar
300 psi
Hydraulic Standby Pressure 4800—5200 kPa
48—52 bar
696—754 psi
Brake Accumulator Precharge 932—1344 kPa
135—195 psi

NOTE: Both brake pedals operate same brake valve with

a mechanical linkage between them. Pressing
either brake pedal will give you the same system
brake pressure. Brakes are self-bleeding.
The purpose of this test is to check brake accumulator

precharge.

group.
3. Stop engine.
NOTE: Brake pressure indicator light should come on

9025 when brake accumulator pressure drops below
25 specification and approximately 30 applications of
36 either brake pedal.
4. Pump brake pedals approximately 75 times to relieve

hydraulic pressure in brake accumulators.
Specification
Brake Pressure Indicator Light—
Pressure ...................................................................................... 2068 kPa
21 bar
300 psi
Continued on next page DW09104,00000A5 –19–12SEP03–1/3

092005
PN=826
Test

penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
–UN–23AUG88
fluids.
X9811
Any fluid injected into the skin must be
information is available from Deere & Company
Medical Department in Moline, Illinois, U.S.A.
–UN–12SEP03
5. Install tee and quick coupler at test connection point
(2).
T194713A
psi pressure transducers to quick coupler. Perform
Digital Pressure And Temperature Analyzer Installation
1—Brake Accumulators
7. Start engine and run at slow idle until pressure is to 2—Test Connection Point
standby specification.
Specification
Hydraulic Standby—Pressure ......................................... 4800—5200 kPa
48—52 bar
696—754 psi 9025
25
8. Stop engine. 37
NOTE: While pumping brake pedal, accumulator pressure

will drop slowly. The last pressure seen before
pressure drop of (345+ kPa) (3.4+ bar) 50+ psi is
accumulator precharge.
9. Slowly pump brake pedal and record accumulator

precharge where brake pressure drops by (345+ kPa)
(3.4+ bar) 50+ psi. Accumulator precharge pressure
must be within specification.
Continued on next page DW09104,00000A5 –19–12SEP03–2/3

092005
PN=827
Test
Specification
Brake Accumulator Precharge—
Pressure ............................................................................ 932—1344 kPa
9.4—13.4 bar
135—195 psi
10. When pressure drops below precharge specification,

pressure will continue to drop until accumulators are
totally discharged.
11. Replace accumulators if precharge pressure is below

specification. Accumulators are not serviceable.
DW09104,00000A5 –19–12SEP03–3/3
Boom Down Accumulator Precharge Test
SPECIFICATIONS
Pilot Control Pressure 4100—4400 kPa
41—44 bar
600—650 psi
Boom Down Accumulator 932—1344 kPa
Precharge Pressure 9.4—13.4 bar
135—195 psi

9025 JT02156A Digital Pressure and Temperature Analyzer
25
38
The purpose of this test is to check brake accumulator
precharge.

group.
Continued on next page DW09104,00000A4 –19–13OCT03–1/3

092005
PN=828
Test
3.
B—Regulated Pressure Test Port
–UN–07DEC96
T103264D
Continued on next page DW09104,00000A4 –19–13OCT03–2/3
9025
25
39

092005
PN=829
Test
Install JT02156A Digital Pressure Analyzer with 5000 psi

pressure transducers to regulated pressure test port (B)
(S.N. —590067) or (2) (S.N. 590068— ). Perform Digital
4. Start engine and record pressure. Pressure should be

within specification. If pressure is not within
specification, see Pressure Reducing Valve Pressure
Specification
Pilot Control—Pressure .................................................. 4100—4400 kPa
41—44 bar
–UN–10DEC03
600—650 psi
5. Stop engine.
T196177A
6. Record pressure while slowly cycling pilot control lever
to boom up and boom down positions.
NOTE: Boom down accumulator pressure will drop slowly

when cycling lever. The last pressure seen before 2—Regulated Pressure Test Port
pressure drop of (345+ kPa) (3.4+ bar) 50+ psi is 3—Pressure Reducing Adjustment Screw
accumulator precharge. 4—Pressure Reducing Adjustment Locknut
7. Record accumulator precharge where brake pressure
drops by (345+ kPa) (3.4+ bar) 50+ psi. Accumulator
precharge pressure must be within specification.
Specification
Boom Down Accumulator
Precharge—Pressure ........................................................ 932—1344 kPa
9025 9.4—13.4 bar
25 135—195 psi
40
DW09104,00000A4 –19–13OCT03–3/3
Brake Valve Pressure Test

Brake Valve Pressure (pedal 3923—4923 kPa JT05491 Connector (7/16—20 M 37° x 14 M x 1.5 M ORB)
applied) 39—49 bar
569—714 psi
Brake Valve Pressure (pedal 0 kPa
Gauge 0—7 000 kPa (0—70 bar) (0—1000 psi)
released) 0 bar
0 psi

092005
PN=830
Test
1. Install connector (A) in port of front or rear axle.

group.
–UN–17FEB97
NOTE: Both brake pedals operate the same brake valve
with mechanical linkage between them. Pressing
either brake pedal will provide same brake system
T107166B
pressure. Brakes are self-bleeding.
3. With engine running, slowly apply brake pedal and

observe pressure.
A—Connector
Pressure should slowly increase as pedal is depressed

and jump to specification as pedal nears the end of
travel. Pressure must be within specification.
Specification
Brake Valve—Pressure (pedal
applied) ............................................................................ 3923—4923 kPa
39—49 bar
569—714 psi
4. If brake pressure is not within specification, inspect

linkage for full travel and perform Pump Load Sense
Differential and Standby Pressure Test in this group.
5. With brake pedals released, pressure must be at

specification.
Specification
Brake Valve—Pressure (pedal
released) ............................................................................................ 0 kPa
0 bar
9025
0 psi
25
41
6. Remove test fittings.
TX,25,SS3779 –19–13OCT03–2/2

092005
PN=831
Test
Brake Valve Leakage Test
SPECIFICATIONS
Brake Valve Leakage—Maximum 22 ml/min
(brake applied) 3/4 oz/min
Brake Valve Leakage—Maximum 14 ml/min
–UN–27AUG96
(brake released) 1/2 oz/min
ESSENTIAL TOOLS
38H1146 Plug (-6 M ORFS)
T103301B
6 PNLO-S Plug (-6 M ORFS) (Parker No. )

group.
2. Stop engine. Do not depress brake pedal to discharge

accumulator.
3. Disconnect return hose from brake valve to reservoir.

Install plug in brake valve.
4. Assemble test hose from brake valve to appropriate

container.
5. Depress brake pedal and measure leakage from brake

valve return port. Repeat procedure with brake pedal
released. Leakage must be within specification.
Specification
Brake Valve—Leakage—
Maximum (brake applied) ............................................................ 22 ml/min
3/4 oz/min
9025
25 Specification
42 Brake Valve—Leakage—
Maximum (brake released).......................................................... 14 ml/min
1/2 oz/min
6. If leakage is not within specification, see Brake

Accumulator Remove and Install. (Group 1060.)
CED,TX13067,35 –19–13OCT03–1/1

092005
PN=832
Test
Brake Accumulator Inlet Check Valve Leakage Test

Hydraulic Oil Temperature 60—71°C 38H1146 Plug (-6 M ORFS)
140—160°F
Brake Accumulator Inlet Check 1 mL/min (0.034 oz/min) (16 SERVICE EQUIPMENT AND TOOLS
Valve Leakage (maximum) drops per min)
Measuring Container
Stop Watch
9025
25
43

092005
PN=833
Test

group.
2. Stop engine. Do not depress brake pedal to discharge

accumulator.
–UN–27AUG96
CAUTION: Accumulator inlet check valve is
located between inlet fitting and base inlet port.
Only remove inlet line from inlet fitting.
T103302B
Removing inlet fitting from base inlet port will
cause high pressure oil to be released out
accumulator inlet port.
Escaping fluid under pressure can penetrate

skin causing serious injury. Relieve pressure
before disconnecting hydraulic or other lines.
Tighten all connections before applying
pressure. Keep hands and body away from
pinholes and nozzles which eject fluids under
high pressure. Use a piece of cardboard or
paper to search for leaks. Do not use your
hand.
If ANY fluid is injected into skin, it must be

surgically removed within a few hours by a
doctor familiar with this type injury or gangrene
may result.
3. Disconnect inlet line from accumulator inlet fitting and

install plug in inlet line.
4. Measure leakage for one minute. If leakage is greater

9025
25 than specification, see Brake Accumulator Remove and
44 Install. (Group 1060.)
Specification
Brake Accumulator Inlet Check
Valve—Leakage (maximum) ........................ 1 mL/min (0.034 oz/min) (16
drops per min)
CED,TX13067,34 –19–16SEP92–2/2

092005
PN=834
Test
Axle And Pin Disconnect Pressure Test

Axle And Pin Disconnect 5860—6640 kPa 34 474 kPa (345 bar) (5000 psi) Gauge
850—950 psi
ESSENTIAL TOOLS
JT03456 (7/16-20 M JIC X —6 F ORFS) Adapter
38H1030 (—6 M x —6 F x —6 M ORFS) Tee
DW09104,00000B0 –19–06NOV03–1/3
NOTE: The Axle and Pin disconnect circuit operates with

reduced pressure oil from the axle and pin
disconnect valve block. The valve is located on
the inside of the loader frame. It controls pressure
by using an adjustable pressure reducing relief
valve. The valve block is sourced with full system
–UN–15APR99
pressure from the main pump.
The same valve block is used for both axle

disconnect and pin disconnect options. It uses
T121138
individual solenoids to control desired option.
There is no axle disconnect leakage test. Any Pin Disconnect Pressure Test
internal leakage will flow into the axle sump and
increase the oil level until there is leakage at the
axle vent. Oil coming out of the vent is the result
of axle disconnect, differential lock or brake
leakage.
9025
25
–UN–24FEB98
1. Connect test gauge to axle disconnect line at axle or 45
pin disconnect line at loader boom.
T113748B
group.
NOTE: When this test is performed it is important to have Axle Disconnect Pressure Test
system pressure higher than low standby. Pin and
axle disconnect pressure reducing relief valve A—Existing Hydraulic Hose
setting is higher than low standby pressure. B—JT03456 Adaptor (7/16—20 M x —6F ORFS)
Activate boom or bucket function to increase C—38H1030 Tee (—6 M x —6 F x —6 M ORFS)
system pressure.
3. Operate engine at slow idle. Operate boom or bucket

function while actuating axle disconnect.

092005
PN=835
Test
4. Pressure must reach test specifications.
Specification
Axle And Pin Disconnect—
Pressure .......................................................................... 5860—6640 kPa
58.6—65.4 bar
850—950 psi
–UN–06APR99
If pressure is not within specification, adjust pressure
reducing relief valve (A) by loosening hex nut (B) and
turning adjusting screw (C).
T121042B
A—Pressure Reducing Relief Valve Cartridge Axle And Pin Disconnect Valve
B—Hex Nut
C—Adjustment Screw
D—Axle and Pin Disconnect Valve Block
DW09104,00000B0 –19–06NOV03–3/3
Hydraulic Oil Filter Inspection Procedure
ESSENTIAL TOOLS
JT05536 Oil Filter Cutting Tool
9025
25
CED,TX13067,39 –19–16SEP92–1/2
46
1. Remove filter.
2. Pour oil out of filter to inspect for water contamination.
3. Use an oil filter cutting tool to cut top off filter.

–UN–13MAR89
4. Remove filter element and inspect for metal particles

and debris in bottom of filter can.
5. Excessive amounts of brass and steel particles can

T6238AK
indicate a failed hydraulic pump or a pump failure in

progress. A rubber type material can indicate cylinder
packing failure.
CED,TX13067,39 –19–16SEP92–2/2

092005
PN=836
Section 9031
Heating And A/C
Contents
Page

Air Conditioning System Cycle Of
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9031-05-1

Diagnose Air Conditioning System
Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9031-15-1
Diagnose Heater System Malfunctions . . . . .9031-15-5
Group 25—Tests
Air Conditioning System Fittings
Reference Chart . . . . . . . . . . . . . . . . . . . .9031-25-1
Proper Refrigerant Handling . . . . . . . . . . . . .9031-25-3
R134a Refrigerant Cautions . . . . . . . . . . . . .9031-25-3
Refrigerant Hoses And Tubing Inspection . . .9031-25-4
R134a Air Conditioning System Test . . . . . . .9031-25-5
Operating Pressure Diagnostic Chart . . . . . .9031-25-7
Low Pressure Switch Test (S.N. —
590067) . . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-10
High Pressure Switch Test (S.N. —
590067) . . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-12
A/C Binary Pressure Switch Test (S.N.
590068— ). . . . . . . . . . . . . . . . . . . . . . . .9031-25-14
Freeze Control Switch . . . . . . . . . . . . . . . . .9031-25-16
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . .9031-25-17
9031

092005
PN=1
Contents
9031

092005
PN=2
Group 05
Theory Of Operation
Air Conditioning System Cycle Of Operation
2
1
5 4
7
8
6
9
–UN–20JUN01
10
11
T142307
T142307
1—Evaporator Core 4—Circulation Blower Motor 7—High Pressure Liquid 10—Low Pressure Gas
2—Compressor 5—Expansion Valve 8—High Pressure Gas 11—Air Flow
3—Condenser Core 6—Receiver-Dryer 9—Low Pressure Liquid 9031
05
1
The compressor is belt driven and engaged by an temperature of refrigerant to rise higher than that of
electro-magnetic clutch. The air conditioning circuit outside air.
automatically controls compressor engagement or
disengagement when system is in operation. See High pressure gas leaves compressor and flows
System Functional Schematic (S.N. —590067) (Group through condenser where heat is removed and
9015A-10) or see Flex Load Controller (FLC) Circuit transferred to outside air being drawn through
Theory of Operation (S.N. 590068— ). (Group condenser core by fan. Cooling refrigerant causes it to
9015B-15.) condense and refrigerant leaves condenser as high
pressure liquid.
Compressor draws low pressure gas from evaporator
and compresses it into high pressure gas. This causes
Continued on next page OUO1065,0000531 –19–14MAY01–1/2

092005
PN=839
Theory Of Operation
High pressure liquid flows into receiver-dryer where A freeze control switch senses temperature of
moisture and contaminants (acid, solids, etc.) are evaporator coil through a capillary tube. This prevents
removed. Receiver-dryer may contain a color moisture the evaporator from becoming cold enough to freeze
indicator. Blue indicates no moisture is present. Pink moisture that condenses on evaporator coil.
indicates moisture is present. Should moisture be Condensed moisture is drained away through drain
combined with refrigerant, hydrofluoric and tubes connected to drain pan under evaporator.
hydrochloric acids are formed. These acids are very
corrosive to metal surfaces and leakage will eventually System pressure is monitored by high and low
develop. Receiver-dryer also stores refrigerant allowing pressure switches, located on high pressure side of
a longer period of time before additional refrigerant is expansion valve. If pressure becomes too high or too
needed. Refrigerant hoses allow a small amount of low the switch opens and stops compressor,
refrigerant to migrate through their walls. interrupting the cycle.
Refrigerant flows from receiver-dryer through Accumulator (if equipped) is located between
expansion valve to evaporator. Expansion valve evaporator and compressor in low pressure gas hose
senses refrigerant temperature and pressure to to retain a quantity of oil to protect compressor from a
modulate refrigerant flow. Expansion valve changes dry start after long periods of not being used.
refrigerant to low pressure liquid entering evaporator.
Actual cooling and drying of cab air takes place at See Blower And A/C Harness (W20) Component
evaporator. Heat absorbed by evaporator and Location (S.N. —590067) (Group 9015A-10.) or see
transferred to refrigerant causes refrigerant to vaporize Blower And A/C Harness (W20) Component Location
into low pressure gas. Low pressure gas is drawn from (S.N. 590068— ) (Group 9015B-10.) for location of
evaporator by compressor and cycle is repeated. machine heater and A/C components.
OUO1065,0000531 –19–14MAY01–2/2
9031
05
2

092005
PN=840
Group 15
Diagnose Air Conditioning System

Malfunctions
Air Conditioning System Does Blower Motor Fuse Replace fuse. See Fuse and Relay
Not Operate Specifications (S.N. —590067)
(Group 9015A-10.) or see Fuse and
). (Group 9015B-10.)
Pressurizer Motor Fuse Replace fuse. See Fuse and Relay

Specifications (Group 9015A-10.) or
see Fuse and Relay Specifications
(S.N. 590068— ). (Group 9015B-10.)
Blower/Pressurizer Motor Relay Check Blower/Pressurizer Motor

(S.N. —590067) Relay. See Fuse and Relay
Specifications (Group 9015A-10.) or
see Fuse and Relay Specifications
(S.N. 590068— ). (Group 9015B-10.)
Blower Speed Switch (S21) Check Blower Speed Switch. See

(S.N. —590067) (Group 9015A-10.)
or System Functional Schematic and
(Group 9015B-10.)
Blower Speed Resistor (R3) Check Blower Speed Resistor. See

Blower And A/C Harness (W20)
590067) (Group 9015A-10.) or see
). (Group 9015B-10.)
Main Blower Motor (M6) Check Main Blower Motor. See 9031
Blower And A/C Harness (W20) 15
Component Location (S.N. — 1
590067). (Group 9015A-10.) or see
). (Group 9015B-10.)
Continued on next page CED,OUOE012,234 –19–02AUG99–1/4

092005
PN=841
Pressurizer Blower Motor (M7) Check Pressurizer Blower Motor.

See Blower And A/C Harness (W20)
590067). (Group 9015A-10.) or see
). (Group 9015B-10.)
A/C (On/Off) Switch (S22) Check A/C (On/Off) Switch. See

590067). (Group 9015A-10.) or see
Flex Load Controller (FLC) Circuit
). (Group 9015B-15.)
Freeze Control Switch (B35) Check Freeze Control Switch. See

590067). (Group 9015A-10.) or see
). (Group 9015B-10.)
A/C Low Pressure Switch (B36) Check Air Conditioner Low Pressure
(S.N. —590067) Switch. See Low Pressure Switch
Test (S.N. —590067). (Group
9031-25.)
A/C High Pressure Switch (B37) Check Air Conditioner High Pressure
(S.N. —590067) Switch. See High Pressure Switch
Test (S.N. —590067). (Group
9031-25.)
A/C Binary Pressure Switch (B50) Check Air Conditioner Binary

(S.N. 590068—) Pressure Switch. See A/C Binary
9031
15 Pressure Switch Test (S.N.
2 590068— ). (Group 9031-25.)

092005
PN=842
A/C Compressor Clutch (Y16) Check Air Conditioner Clutch. See

Engine Harness (W6) Component
Location Diagram (S.N. —590067)
(Group 9015A-10.) or Engine
Diagram (S.N. 590068— ). (Group
9015B-10.)
A/C Clutch 1 A Diode (V11) See Air Conditioning Compressor

Clutch Diode. See Engine Harness
(W6) Component Location Diagram
(S.N. —590067) (Group 9015A-10.)
or Engine Harness (W6) Component
Location Diagram (S.N. 590068— ).
(Group 9015B-10.)
Wiring harness See Connectors For Blower And A/C

Harness (W20) (Group 9015A-10.)
or see Blower And A/C Harness
590068— ). (Group 9015B-10.)
Air Conditioner Does Not Cool Fresh air filter clogged Clean or replace filter
Interior of Cab
Condenser fins clogged with debris Clean condenser fins
Recirculating air filter clogged Clean or replace filter
Refrigerant hose kinked, pinched or Re-route or re-index hoses, replace

collapsed kinked or collapsed hoses
Heater or evaporator core fins Clean heater or evaporator core fins

clogged with dirt or dust
Blower motor failed or operating too Check Pressurizer Blower Motor.

9031
slowly See Blower And A/C Harness (W20) 15
Component Location (S.N. — 3
590067) (Group 9015A-10.) or see
). (Group 9015B-10.)
Compressor belt slipping or failed Inspect and/or replace compressor

clutch

092005
PN=843
Warm outside air leaking into cab Inspect, repair or replace door and
window seals
Heater valve remaining open Inspect, repair, adjust or replace

heater valve or cable
System refrigerant (R134a) charge Inspect system for leaks, then

low recharge. See Charge R134a
System. (Go to Group 18-1830 in
Repair Manual.)
Evaporator fins frosting or freezing Thermostat switch capillary tube not

positioned correctly in evaporator
core
Air Conditioner Runs Constantly, A/C Thermostat Switch capillary tube Reposition capillary tube in
Too Cold not positioned in evaporator properly evaporator core
Compressor clutch engaged See Freeze Control Switch. (Group

constantly 9031-10.)
Interior Windows Continue To Fresh air filter clogged Clean or replace filter.
Fog
A/C system off Turn A/C (on/off) switch on.
CED,OUOE012,234 –19–02AUG99–4/4
9031
15
4

092005
PN=844
Diagnose Heater System Malfunctions

Heater System Does Not Operate Blower motor fuse Replace circuit breaker. See Fuse
and Relay Specifications (S.N. —
590067) (Group 9015A-10.) or see
Fuse and Relay Specifications (S.N.
590068— ). (Group 9015B-10.)
Blower speed switch Check Blower Speed Switch. See

590067). (Group 9015A-10.) or see
). (Group 9015B-10.)
Wiring harness Check wiring harness
Heater Does Not Warm Interior Fresh air filter clogged Clean or replace filter
Of Cab
Recirculating air filter clogged Clean or replace filter
Heater hose kinked, pinched or Re-route or re-index hoses, replace

collapsed collapsed hoses
Heater core fins clogged with dirt or Clean heater fins

dust
Main blower motor failed or Check Main Blower Motor. See

operating too slowly Blower And A/C Harness (W20)
590067) (Group 9015A-10.) or see
). (Group 9015B-10.)
9031
15
Heater valve remaining closed Inspect, repair, adjust or replace 5
heater valve or cable
Interior Windows Continue To Fresh air filter clogged Clean or replace filter
Fog
A/C system off (if equipped) Turn A/C (on/off) switch on (if
equipped)
TX,15,JC1693 –19–11NOV96–1/1

092005
PN=845
9031
15
6

092005
PN=846
Group 25
Tests
Air Conditioning System Fittings Reference

Chart

JT02098 Flush Fitting Kit
The JT02098 Flush Fitting Kit contains fittings for flushing

or leak testing sections or individual components to the air
conditioning system. Following chart lists service fittings
used at each specific location.
9031
25
1

092005
PN=847
Tests
Location Size ServiceGard Number O-Ring Number

Compressor Manifold:
1. Suction Port (F) 7/8—18 JT02099 R113050
2. Discharge Port (F) 3/4—18 JT02100
Compressor Discharge Hose:
3. Inlet End (M) 3/4—18 JT02102 R113050
4. Outlet End (F) 3/4—18 JT02100 R113050
Condenser:
5. Inlet Port (M) 3/4—18 JT02102
6. Outlet Port (M) 5/8—18 JT03183
Condenser to Receiver-Dryer Hose:
7. Inlet End (F) 5/8—18 JT03188 R10093
8. Outlet End (M) 5/8—18 JT03197 R10093
Receiver-Dryer:
9. Inlet Port (F) 5/8—18 JT03196 or JT02110
10. Outlet Port (M) 5/8—18 JT03183
Receiver-Dryer to Evaporator Hose:
11. Inlet End (F) 5/8—18 JT03188 R10093
12. Outlet End (M) 5/8—18 JT03183
A/C Inlet Tube
13. Inlet End (F) 5/8—18 JT03188 R10093
14. Outlet End (M) 3/8 JT02106 and JT02104 R10093
Expansion Valve:
15. Liquid Inlet (F) 3/8 JT02103
16. Liquid Outlet (F) 1/2 JT02104
19. Gas Inlet (F) 5/8 JT02105
20. Gas Outlet (F) 3/4 JT02147
Evaporator Core:
17. Inlet Tube (M) 1/2 JT02106 and JT02103 R113050
18. Outlet Tube (M) 5/8 JT02106 and JT02105 R33259
A/C Outlet Tube:
21. Inlet End (M) 3/4 TEV and JT02105 T143169
9031 22. Outlet End (F) 1-1/16—14 Not Available T143169

25 Evaporator to Compressor Hose
2
23. Inlet End (M) 1-1/16—14 Not Available
24. Outlet End (M) 7/8—18 JT02101 R33259
CED,OUOE012,235 –19–02AUG99–2/2

092005
PN=848
Tests
Proper Refrigerant Handling
The U.S. Environmental Protection Agency prohibits

discharge of any refrigerant into the atmosphere, and
requires that refrigerant be recovered using the approved
recovery equipment.
IMPORTANT: Use correct refrigerant recovery,

recycling and charging stations. DO
NOT use refrigerant, hoses, fittings,
components or refrigerant oils intended
for use with R12 refrigerant.
Recovery, recycling and charging stations for R12 and

R134a refrigerants MUST NOT be interchanged. Systems
containing R12 refrigerant use a different oil than systems
using R134a. Certain seals are not compatible with both
types of refrigerants.
MODTX9031QQ2009 –19–19AUG94–1/1
R134a Refrigerant Cautions
SPECIFICATIONS DO NOT heat refrigerant over 52°C (125°F) in

Maximum Amount To Heat 52°C (125°F) a closed container. Heated refrigerant will
Refrigerant In Closed Container develop high pressure which can burst the
Temperature container.
Specification
CAUTION: DO NOT allow liquid refrigerant to Maximum Amount To Heat
contact eyes or skin. Liquid refrigerant will Refrigerant In Closed 9031
freeze eyes or skin on contact. Wear Container—Temperature ................................................ 52°C (125°F) 25
goggles, gloves and protective clothing. 3
Keep refrigerant containers away from heat sources.
If liquid refrigerant contacts eyes or skin, DO Store refrigerant in a cool place.
NOT rub the area. Splash large amounts of
COOL water on affected area. Go to a DO NOT handle damp refrigerant container with your
physician or hospital immediately for bare hands. Skin may freeze to container. Wear
treatment. gloves.
DO NOT allow refrigerant to contact open If skin freezes to container, pour COOL water over
flames or very hot surfaces such as electric container to free the skin. Go to a physician or hospital
welding arc, electric heating element and immediately for treatment.
lighted smoking materials.
TX,9031,JC1705 –19–12NOV96–1/1

092005
PN=849
Tests
Refrigerant Hoses And Tubing Inspection
When a component is disconnected from the system, hose and tube connections. Dip O-rings in correct
special care should be given to inspecting hoses and viscosity oil before assembling.
tubing for moisture, grease, dirt, rust, or other foreign
material. If such contamination is present in hoses, IMPORTANT: Hose used for air conditioning
tubing, or fittings and cannot be removed by cleaning, systems contains special barriers in
then replace parts. its walls to prevent migration of
refrigerant gas.
Fittings that have grease or dirt on them should be
wiped clean with a cloth dampened with alcohol. DO NOT use hydraulic hoses as
Chlorinated solvents (such as trichloroethylene) are replacement hoses in the air
contaminants, and must not be used for cleaning. conditioning system. Use ONLY
certified hose meeting SAE J51B
To assist in making leak-proof joints, use a small requirements.
amount of clean correct viscosity refrigerant oil on all
MODTX9031QQ1882 –19–17JUN94–1/1
9031
25
4

092005
PN=850
Tests
R134a Air Conditioning System Test
SPECIFICATIONS
Cab Position Open
Engine rpm 2000 rpm
Temperature Control Switch Maximum
Position
Blower Speed High
Run Unit Time At least 5 minutes
ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station
Ambient Temperature Air Duct Temperature Low Pressure Gauge High Pressure Gauge
15.6—21.1°C (60—70°F) 10°C (50°F) 48.3—103 kPa 655—862 kPa
(0.48—1.03 bar) (6.55—8.62 bar)
(7—15 psi) (95—125 psi)
21.1—26.7°C (70—80°F) 11°C (52°F) 68.9—124 kPa 724—1275 kPa
(0.69—1.24 bar) (7.24—12.76 bar)
(10—18 psi) (105—185 psi)
26.7—32.2°C (80—90°F) 12.8°C (55°F) 82.7—138 kPa 827—1620 kPa
(0.83—1.38 bar) (8.27—16.20 bar)
(12—20 psi) (120—235 psi)
32.2—37.8°C (90—100°F) 15.6°C (60°F) 103—152 kPa 1241—1861 kPa
1.03—1.52 bar) 12.41—18.62 bar)
(15—22 psi) (180—270 psi)
37.8—43.4°C (100—110°F) 18.3°C (65°F) 117—172 kPa 1586—1999 kPa
(1.17—1.72 bar) (15.86—19.99 bar)
(17—25 psi) (340—290 psi)
NOTE: JTO2046 and JTO2050 Recovery and Charging

Stations can be substituted for the JTO2045
station.
IMPORTANT: Use correct refrigerant recovery, 9031

recycling and charging stations. DO 25
NOT use refrigerant, hoses, fittings, 5
components or refrigerant oils intended
for R12 refrigerant.
1. Connect refrigerant recovery, recycling and charging

station. See R134a Refrigerant Recovery, Recycling
And Charging Station Installation Procedure. (Go to
this group.)
Continued on next page TX,9031,JC1706 –19–12NOV96–1/3

092005
PN=851
Tests
2. Close both low and high pressure valves on refrigerant

recovery, recycling and charging station.
3. Open cab doors and windows.
Specification
Cab—Position .................................................................................... Open
TX,9031,JC1706 –19–12NOV96–2/3
4. Start engine and run at rated engine speed.
Specification
Engine—rpm ................................................................................ 2000 rpm
5. Turn temperature control switch to the maximum

cooling position.
Specification
Temperature Control Switch—
Position ........................................................................................ Maximum
6. Turn blower switch to high speed.
Specification
Blower—Speed .................................................................................... High
7. Check sight glass in receiver-dryer to condenser line.
8. Run unit for at least 5 minutes.
Specification
–UN–06DEC93
Run Unit—Time ............................................................. At least 5 minutes
9. Measure air temperature at condenser air inlet and at

9031
air ducts in air conditioning unit.
T8118AG
25
6
10. Compare air duct temperature reading to the
temperatures shown in the specifications.
A—High Pressure Hose Charge Port Cap
B—Red Hose (High Pressure)
11. Observe low-side pressure (C) and high-side pressure C—Blue Hose (Low Pressure)
(B) on gauges. D—High Pressure Relief Valve
E—Refrigerant Recovery/Recycling and Charging
12. Compare pressure readings to the pressure shown in System
specifications.
See Operating Pressure Diagnostic Chart. (This Group.)
TX,9031,JC1706 –19–12NOV96–3/3

092005
PN=852
Tests
Operating Pressure Diagnostic Chart
NOTE: Inspection of the sight glass will not give proper

indicators of air conditioning concerns on R134a
systems.
OPERATING PRESSURE DIAGNOSTIC CHART

Low Side Pressure High Side Pressure Problem Solution
Low Low or Normal Loss of refrigerant. Leak in system. Do leak test. Add refrigerant. Normal
migration through hoses. Add refrigerant.
Low Low or Normal Loss of refrigerant. Leak in system. Do leak test. Repair leak. Add refrigerant
in this group.
Low Low or Normal Loss of refrigerant. Normal migration through hoses. Add refrigerant in this
group
Low Low or Normal Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a
1. Between compressor temperature change. Remove refrigerant by recovery
and condenser. method. Inspect and clean each component.
2. Inside condenser.
3. Between condenser and
receiver/dryer.
4. Inside receiver/dryer.
Low Low or Normal Blower motor running too Check for motor shaft binding or defective electrical
slow. connections.
Low Low or Normal Evaporator core dirty or air Clean evaporator and straighten fins.
flow through evaporator
restricted.
Low Low or Normal Expansion valve Replace expansion valve.
malfunction.
Low Low or Normal Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a
1. Between receiver/dryer temperature change. Remove refrigerant by recovery
and expansion valve. method. Inspect and clean each component.
2. Between expansion
valve and evaporator.
3. Between evaporator and
compressor.
Low Low or Normal Moisture in system. Remove refrigerant using recovery method, evacuate and
charge the system. See Recover R134a System.See
Evacuate R134a System. See Charge R134a System.
(Group 1830.)
Low High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a
9031
25
7
receiver/dryer.
5. Between receiver/dryer
and expansion valve.
Normal Normal Heater valve not closing. Close heater shut-off valve on engine block or clamp
heater hoses shut
Continued on next page TX,9031,SS3610 –19–07JUL00–1/3

092005
PN=853
Tests

Normal Normal Expansion valve Replace expansion valve.
malfunction.
Normal Normal Moisture in system Remove refrigerant using recovery method, evacuate and
(intermittent cooling below charge the system. See Recover R134a System. See
27°C [80°F] ambient). Evacuate R134a System. See Charge R134a System. (Go
to Group 1830 in Repair Manual.)
Normal Normal Loss of refrigerant. Leak in system. Do leak test. Repair leak. Add refrigerant.
Normal Normal Loss of refrigerant Normal migration through hoses. Add refrigerant in this
group.
Normal Normal Air is system. Remove refrigerant using recovery method, evacuate and
charge the system. See Recover R134a System. See
(Group 1830.)
Normal High Restricted air flow through Inspect for debris. Straighten fins.
condenser or radiator.
Normal High Overcharge of refrigerant. Start engine and run at fast idle. Operate air conditioner at
maximum cooling. Remove refrigerant from low-side of
system using recovery operation until bubbles appear in
sight glass. Add 0.7 kg (1.5 lb) of refrigerant through
low-side valve.
Normal High Expansion valve Replace expansion valve.
malfunction.
Normal High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a
receiver/dryer.
Normal High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a
receiver/dryer.
High Low Compressor belt loose. Tighten belt.
High Low Compressor clutch slipping. Check for battery voltage at compressor clutch with clutch
9031 engaged. Clean electrical connections or replace relay.
25
High Low Compressor clutch slipping. Inspect and repair clutch.
8
High Low Compressor failure. See Compressor Remove and Install.(Group 1830.)
High Normal Expansion valve Replace expansion valve.
malfunction.
High High Restricted air flow through Inspect for debris. Straighten fins.
condenser or radiator.
High High Expansion valve Replace expansion valve.
malfunction.
Continued on next page TX,9031,SS3610 –19–07JUL00–2/3

092005
PN=854
Tests

High High Overcharge of refrigerant. Start engine and run at fast idle. Operate air conditioner at
maximum cooling. Remove refrigerant from low-side of
system using refrigerant recovery method until bubbles
appear in sight glass. Add 0.7 kg (1.5 lb) of refrigerant
through low-side valve.
High High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a
temperature change. Remove refrigerant by recovery
method. Inspect and clean each component.
High High Air in system. Remove refrigerant using recovery method, evacuate and
charge the system. See Recover R134a System.See
(Group 1830.)
High High Restriction in system: Inspect for bent, kinked, or dented lines. Feel lines for a
receiver/dryer.
TX,9031,SS3610 –19–07JUL00–3/3
9031
25
9

092005
PN=855
Tests
Low Pressure Switch Test (S.N. —590067)
SPECIFICATIONS
Low Pressure Switch Opening 173 ± 35 kPa (1.73 ± 0.3 bar) (25
Pressure ± 5 psi)
Low Pressure Switch (Normally 345 ± 35 kPa (3.45 ± 0.3 bar) (50
Open) Closing Pressure ± 5 psi)
ESSENTIAL TOOLS
JT02148 Straight Connector

Multimeter
NOTE: Low pressure switch is normally open when

removed from machine. When installed the switch
becomes closed because of normal system
pressure.
• Turn key switch on but do not start engine. Turn blower
–UN–08JUL97
switch on. Turn temperature control switch to the
maximum cooling position.
• Disconnect and connect low pressure switch at harness
connector. Compressor clutch must engage and
T110369B
disengage (click).
NOTE: The line that attaches the low pressure switch has
a valve to prevent discharging the air conditioning
system when switch is removed.
• Disconnect harness from switch and remove switch

from line. Connect low pressure switch to harness.
–UN–06MAR95
Specification
Low Pressure Switch—Opening
Pressure .............................................................................. 138—208 kPa
1.38—2.08 bar
20—30 psi
T8426AD
9031 Low Pressure Switch (Normally
25 Open)—Closing Pressure................................................... 315—380 kPa
10 3.15—3.80 bar
45—55 psi A—Low Pressure Switch
B—High Pressure Switch
Compressor clutch must not engage (click).
• The actual pressure setting of switch can be checked

by connecting it to a pressure source such as a
regulated air supply or dry nitrogen.
Continued on next page TX18076,0000014 –19–14NOV00–1/2

092005
PN=856
Tests
• Switch must not have continuity between terminals until

pressure increases to switch closing pressure
specification. Slowly release pressure. Switch must
have continuity until pressure decreases to switch
opening pressure specification.
TX18076,0000014 –19–14NOV00–2/2
9031
25
11

092005
PN=857
Tests
High Pressure Switch Test (S.N. —590067)
SPECIFICATIONS
High Pressure Switch Opening 2622—2898 kPa
380—420 psi
High Pressure Switch (Normally 1172—1448 kPa
Closed) Closing Pressure 11.72—14.48 bar
170—210 psi
ESSENTIAL TOOLS
JT02148 Straight Connector For Switch Testing

Multimeter
ESSENTIAL TOOLS
JT02148 Straight Connector For Switch Testing
–UN–08JUL97
Multimeter
NOTE: The line that attaches the high pressure switch

has a valve installed to prevent discharging the air
T110369B
conditioning system when switch is removed. The
high pressure switch is normally closed when
removed from the machine. It does not open
when installed in the A/C system until pressure
exceeds specification.
• Remove high pressure switch.

• Connect a portable pressure source, such as dry
nitrogen, to high pressure switch.
–UN–06MAR95
Specification
High Pressure Switch—Opening
Pressure .......................................................................... 2622—2898 kPa
26.2—29.0 bar
T8426AE
9031 380—420 psi
25 High Pressure Switch (Normally
12 Closed)—Closing Pressure ............................................. 1172—1448 kPa
11.72—14.48 bar A—Low Pressure Switch
170—210 psi B—High Pressure Switch
• Switch must have continuity between terminals until

pressure increases to switch opening pressure
specification.
Continued on next page TX18076,0000015 –19–14NOV00–1/2

092005
PN=858
Tests
• Slowly release pressure. Switch must not have

continuity until pressure decreases to switch closing
pressure specification.
• The switch can also be checked when installed in air
conditioning system, however, pressure is slow to
increase to test specification.
Connect an air conditioning gauge set to service fittings
at compressor. Cover condenser with paper or plastic to
stop air flow. Operate air conditioner on maximum
cooling. Note high-side pressure when high pressure
switch opens and then closes.
TX18076,0000015 –19–14NOV00–2/2
9031
25
13

092005
PN=859
Tests
A/C Binary Pressure Switch Test (S.N.

590068— )
SPECIFICATIONS
Low Pressure Opening Pressure 137.9—227.5 kPa
Low Pressure 1.379—2.275 bar
–UN–06MAR95
20—33 psi
Low Pressure (Normally Open) 158.6—255.1 kPa
Closing Pressure 1.586—2.551 bar
Low Pressure (Normally Open) 23—37 psi
T8426AD
2620—2895 kPa
High Pressure 26.20—28.95 bar
380—420 psi
High Pressure (Normally Closed) 1379—2068 kPa
Closing Pressure 13.79—20.68 bar
200—300 psi
ESSENTIAL TOOLS
JT02148 Straight Connector

Multimeter
NOTE: Low pressure switch is normally open when

removed from machine. When installed the switch
becomes closed because of normal system
pressure.
• Turn key switch on but do not start engine. Turn blower

switch on. Turn temperature control switch to the
maximum cooling position.
• Disconnect and connect low pressure switch at harness
connector. Compressor clutch must engage and
disengage (click).
NOTE: The line that attaches the low pressure switch has
a valve to prevent discharging the air conditioning
9031 system when switch is removed.
25
14
• Disconnect harness from switch and remove switch
from line. Connect low pressure switch to harness.
Specification
Low Pressure—Opening Pressure ............................... 137.9—227.5 kPa
1.379—2.275 bar
20—33 psi
Continued on next page DW70185,0000003 –19–13DEC04–1/2

092005
PN=860
Tests
Specification
Low Pressure (Normally Open)—
Closing Pressure ........................................................... 158.6—255.1 kPa
1.586—2.551 bar
23—37 psi
Compressor clutch must not engage (click).
• The actual pressure setting of switch can be checked

by connecting it to a pressure source such as a
regulated air supply or dry nitrogen.
• Switch must not have continuity between terminals until
pressure increases to switch closing pressure
specification. Slowly release pressure. Switch must
have continuity until pressure decreases to switch
opening pressure specification.
• Connect a portable pressure source, such as dry

nitrogen, to switch.
Specification
High Pressure—Opening
Pressure .......................................................................... 2620—2895 kPa
26.20—28.95 bar
380—420 psi
High Pressure (Normally
Closed)—Closing Pressure ............................................. 1379—2068 kPa
13.79—20.68 bar
200—300 psi
• Switch must have continuity between terminals until

pressure increases to switch opening pressure
specification.
• Slowly release pressure. Switch must not have
continuity until pressure decreases to switch closing
pressure specification.
• The switch can also be checked when installed in air
conditioning system, however, pressure is slow to
increase to test specification.
Connect an air conditioning gauge set to service fittings
at compressor. Cover condenser with paper or plastic to 9031
25
stop air flow. Operate air conditioner on maximum
15
cooling. Note high-side pressure when high pressure
switch opens and then closes.
DW70185,0000003 –19–13DEC04–2/2

092005
PN=861
Tests
Freeze Control Switch
SPECIFICATIONS
Freeze Control Switch (Normally -1.4°C
Closed) Opens As Temperature 29.5°F
Drops Opening Temperature
–UN–13NOV90
Freeze Control Switch (Normally 2.22°C
Closed) Closes As Temperature 36°F
Rises Closing Temperature
T7199EZ
• Remove freeze control switch from evaporator.
• Connect ohmmeter to switch terminals. Switch must be
closed at room temperature.
• Put switch into a freezer (temperature must be below
-0.56 ± 0.84°C [31 ± 1.5°F]). Switch must open, and
continuity must not be read.
Specification
Freeze Control Switch (Normally
Closed) Opens As Temperature
Drops—Opening Temperature ......................................................... -1.4°C
29.5°F
• Remove switch from freezer. Put sensing tube into a

glass of warm water. Switch must close, and continuity
must be read.
Specification
Freeze Control Switch (Normally
Closed) Closes As Temperature
Rises—Closing Temperature .......................................................... 2.22°C
36°F
• If switch does not open and close during testing, install

new switch.
9031
25
16
TX18076,0000016 –19–14NOV00–1/1

092005
PN=862
Tests
Leak Testing
SPECIFICATIONS • If a leak detector is used, move the leak detector

Move Leak Detector Speed 25 mm (1 in.) per second probe under the hoses and around the connections
at a rate of 25 mm (1 in.) per second.
• Inspect all lines, fittings, and components for oily or
Specification
dusty spots. When refrigerant leaks from the system,
Move Leak Detector—Speed ..................... 25 mm (1 in.) per second
a small amount of oil is carried out with it.
• A soap and water solution can be sprayed on the
• Some refrigerant manufacturers add dye to
components in the system to form bubbles at the
refrigerant to aid in leak detection.
source of the leak.
MODTX9031QQ1881 –19–19AUG94–1/1
9031
25
17

092005
PN=863
Tests
9031
25
18

092005
PN=864
Index
Page Page
A Axle breather
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-39
Accesory menu Axle circulation
Clutch Cutoff (A 01) . . . . . . . . . . . . . 9015A-15-11 Motor
Accessory menu Pumps . . . . . . . . . . . . . . . . . . . . . . . .9020-05-15
Auto mode to first (A 03). . . . . . . . . . 9015A-15-16 Axle circulation dual pump
Job timer mode (A 04) . . . . . . . . . . . 9015A-15-17 Flow and temperature tests. . . . . . . . . .9020-25-36
Metric units mode (A 07). . . . . . . . . . 9015A-15-19 Axle circulation pump
Quick shift mode (A 02) . . . . . . . . . . 9015A-15-13 Inlet suction test . . . . . . . . . . . . . . . . . .9020-25-40
Stop watch mode (A 05) . . . . . . . . . . 9015A-15-17 Axle disconnect
Accumulator, brake Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-30
Precharge test . . . . . . . . . . . . . . . . . . .9025-25-36 Axle disconnect circuit . . . . . . . . . . . . . . 9015B-15-9
Axle motor
Acid burns . . . . . . . . . . . . . . . . . . . . . . 9015B-20-50
Circulation. . . . . . . . . . . . . . . . . . . . . . .9020-05-15
Adjustment
Axle pumps
Clutch cutoff sensor . . . . . . . . . . . . . 9015A-20-94
Circulation. . . . . . . . . . . . . . . . . . . . . . .9020-05-15
Air conditioning
Axle Recirculation Motor
Component location drawing . . . . . . . 9015A-10-57
Flow Test . . . . . . . . . . . . . . . . . . . . . . .9020-25-38
Diagnose malfunctions . . . . . . . . . . . . . .9031-15-1
Freeze control switch test . . . . . . . . . . .9031-25-16
High pressure switch test . . . . . . . . . . .9031-25-12
Hoses and tubing inspection . . . . . . . . . .9031-25-4 B
Leak testing . . . . . . . . . . . . . . . . . . . . .9031-25-17
Low pressure switch test. . . . . . . . . . . 9031-25-10,
Backup alarm
9031-25-14
Change volume. . . . . . . . . . . . . . . . . 9015B-20-65
Pressure diagnostic chart . . . . . . . . . . . .9031-25-7
Battery
Refrigerant cycle . . . . . . . . . . . . . . . . . . .9031-05-1
Acid burns. . . . . . . . . . . . . . . . . . . . . 9015B-20-50
Refrigerant handling . . . . . . . . . . . . . . . .9031-25-3
Electrolyte level. . . . . . . . . . . . . . . . . 9015A-20-88
Refrigerant R134a caution . . . . . . . . . . .9031-25-3 Electrolyte level check. . . . . . . . . . . . 9015B-20-50
System Test . . . . . . . . . . . . . . . . . . . . . .9031-25-5 Explosion . . . . . . . . . . . . . . . . . . . . . 9015B-20-50
Air conditioning (A/C) circuit . . . . . . . . . . 9015B-15-9 Terminals . . . . . . . . . . . . . . . . . . . . . 9015B-20-50
Air conditioning system Testing . . . . . . . . . . . . 9015A-20-91, 9015B-20-52
Fittings reference chart . . . . . . . . . . . . . .9031-25-1 Battery (Cables) Harness
Air filter restriction indicator switch test. . . .9010-25-4 Component Location . . . . . . . . . . . . . 9015A-10-64
Air intake system leakage test . . . . . . . . . .9010-25-3 Battery monitor (d 03)
Alarm, backup Diagnostics menu . . . . . . . . . . . . . . . 9015A-15-25
Change volume. . . . . . . . . . . . . . . . . 9015B-20-65 Battery monitoring signals
Alternators and starting motors Chassis computer unit. . . . . . . . . . . . 9015A-15-51
Use CTM77 . . . . . . . . . . . . . . . . . . . . 9015A-20-1 Blade terminals
Analog throttle position sensor Remove . . . . . . . . . . . . . . . . . . . . . .9015A-20-127
Adjustment . . . . . . . . . . . . . . . . . . . . 9015A-20-99 Blower and A/C harness (W19)
Anti-Cavitation Valve Component location . . . . . . . . . . . . . 9015B-10-72
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-65 Wiring diagram . . . . . . . . . . . . . . . . . 9015B-10-74 Indx
Artwork 1
Boom
Hydraulic circuit symbols. . . . . . . . . . . . .9025-15-1 Height kickout adjustment . . . . . . . . .9015A-20-101
Auto mode to first (A 03) Boom down operation
Accessory menu . . . . . . . . . . . . . . . . 9015A-15-16 Pressure reducing valve . . . . . . . . . . . .9025-05-21
Auxiliary section Boom down solenoid valve
Auxiliary operating and boom raise . . . .9025-05-48 Remove and install . . . . . . . . . . . . . .9015A-20-129
Stroke Adjuster Operation (If Boom Float
equipped) . . . . . . . . . . . . . . . . . . . . .9025-05-50 Pilot Controller . . . . . . . . . . . . . . . . . . .9025-05-30
Axle and pin disconnect circuit Boom height kickout
Pressure test. . . . . . . . . . . . . . . . . . . . .9025-25-45 Adjustment . . . . . . . . . . . . . . . . . . . . 9015B-20-61
TM2075 (03MAR05) Index-1 644J and 724J Loader

092005
PN=1
Index
Page Page
Boom height kickout (BHKO) circuit . . . . 9015B-15-9 Cinch connector (32 and 48 Way)
Boom Height Kickout Theory of Repair . . . . . . . . . . . . . . . . . . . . . . . . 9015B-20-77
Operation . . . . . . . . . . . . . . . . . . . . . 9015A-15-73 Cinch connectors
Boom section Replace Connector . . . . . . . . . . . . . . 9015B-20-74
Boom down and steering operation. . . .9025-05-42 Circuit
Boom raise and bucket dump . . . . . . . .9025-05-44 Modulation . . . . . . . . . . . . . . . . . . . . . . .9020-05-9
Brake Circuit relief valve
Valve . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-28 Pressure test. . . . . . . . . . . . . . . . . . . . .9025-25-19
Brake accumulator Circuit relief valve operation . . . . . . . . . . .9025-05-62
Inlet check valve leakage test . . . . . . . .9025-25-43 Circuit, engine air heater
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-27 Theory of operation. . . . . . . . . . . . . . . . .9010-05-3
Precharge test . . . . . . . . . . . . . . . . . . .9025-25-36 Circuit, start
Brake hydraulic system . . . . . . . . . . . . . .9025-05-26 Theory Of Operation . . . . . . . . . . . . . . 9015A-15-1
Brake valve Clutch
Leakage test . . . . . . . . . . . . . . . . . . . . .9025-25-42 Electronic adjustment . . . . . . . . . . . . . . .9020-20-3
Pressure test. . . . . . . . . . . . . . . . . . . . .9025-25-40 Clutch Cutoff (A 01)
Bucket section Accesory menu . . . . . . . . . . . . . . . . . 9015A-15-11
Boom raise and bucket dump . . . . . . . .9025-05-46 Clutch cutoff sensor
Bucket Section Operation Adjustment . . . . . . . . . 9015A-20-94, 9015B-20-60
Tool Carrier. . . . . . . . . . . . . . . . . . . . . .9025-05-51 Check . . . . . . . . . . . . . . . . . . . . . . . . 9015B-20-60
Bypass valve Clutch modulation
Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-14 Transmission. . . . . . . . . . . . . . . . . . . . .9020-05-12
Pressure test. . . . . . . . . . . . . . . . . . . . .9020-25-32 Clutch pressure test
Transmission. . . . . . . . . . . . . . . . . . . . .9020-25-10
Component location
Air conditioning . . . . . . . . . . . . . . . . . 9015A-10-57
C Hydraulic system. . . . . . . . . . . . . . . . . . .9025-15-8
Information . . . . . . . . . . . 9015A-05-2, 9015B-05-2
Cab roof harness (W19) Components
Component location . . . . . . . . . . . . . 9015B-10-68 Transmission control valve . . . . . . . . . . .9020-05-9
Wiring diagram . . . . . . . . . . . . . . . . . 9015B-10-70 Connector
Cab work lights harness (W19) Metri-Pack. . . . . . . . . 9015A-20-106, 9015B-20-67
Component location . . . . . . . . . . . . . 9015A-10-55 Connector body from blade terminals
Camshaft sensor Remove . . . . . . . . . . . . . . . . . . . . . .9015A-20-127
Test . . . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-97 Connector body, transmission control valve
CAN Monitor Unit (CMU) Remove and install . . . . . . . . . . . . . .9015A-20-111
Diagnostic Trouble Codes (DTCs). . . . 9015B-20-6 Connector, Deutsch
Remove and install . . . . . . . . . . . . . . 9015B-20-85 Replace . . . . . . . . . . . . . . . . . . . . . .9015A-20-107
Reprogram . . . . . . . . . . . . . . . . . . . . 9015B-20-85 Connector, transmission control valve
Theory of operation. . . . . . . . . . . . . . 9015B-15-32 Install contact . . . . . . . . . . . . . . . . . .9015A-20-112
CAN Terminator Harness (W37) Connectors
Component Location . . . . . . . . . . . . . 9015A-10-67 WEATHER PACK™. . . . . . . . . . . . . .9015A-20-109
Indx Charge ride control accumulator. . . . . . . . .9025-20-4 Continuity check (d 02)
2
Charging circuit Diagnostics menu . . . . . . . . . . . . . . . 9015A-15-22
Theory of operation. . . . . . . . . . . . . . . 9015B-15-1 Control valve components
Chassis computer unit Transmission. . . . . . . . . . . . . . . . . . . . . .9020-05-9
Intermittent wipers circuit signals. . . . 9015A-15-51 Controller Area Network (CAN)
Turn and flasher light signals . . . . . . 9015A-15-51 Theory of operation. . . . . . . . . . . . . . . 9015B-15-3
Chassis computer unit circuit Converter
Theory Of Operation . . . . . . . . . . . . . 9015A-15-51 Relief pressure . . . . . . . . . . . . . . . . . . .9020-25-24
Cinch connector Converter and power plug harness (W21)
Install contact . . . . . . 9015A-20-126, 9015B-20-76, Component location . . . . . . . . . . . . . 9015A-10-61
9015B-20-77 Converter-in pressure test . . . . . . . . . . . .9020-25-19

092005
PN=2
Index
Page Page
Converter-out Digital pressure and temperature analyzer

Flow test . . . . . . . . . . . . . . . . . . . . . . . .9020-25-26 installation. . . . . . . . . . . . . . . . . . . . . . . .9025-25-1
Pressure test. . . . . . . . . . . . . . . . . . . . .9020-25-21 Drive light circuit. . . . . . . . . . . . . . . . . . . 9015B-15-9
Coolant overheat sensor Drive lights signals . . . . . . . . . . . . . . . . 9015A-15-51
Test . . . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-96 Driveline bearing-park brake
Coolers Drag test . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-4
Axle, differential . . . . . . . . . . . . . . . . . .9020-05-15
Crankshaft sensor
Test . . . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-97
Cycle time test . . . . . . . . . . . . . . . . . . . . .9025-25-35 E
Cylinder, boom and bucket
Leakage test . . . . . . . . . . . . . . . . . . . . .9025-25-24 Electric Air Adjust Seat Harness (W36)
Cylinder, loader Component Location . . . . . . . . . . . . . 9015A-10-66
Drift test . . . . . . . . . . . . . . . . . . . . . . . .9025-25-22 Electrical
Component specifications . . . . . . . . . 9015A-20-81,
9015B-20-54
Fuse Specifications . . . . . 9015A-10-1, 9015B-10-2
D Schematic, wiring diagram, and component
location information . . . 9015A-05-2, 9015B-05-2
Deutsch connectors Electronic clutch adjustment
Replace . . . . . . . . . . . . . . . . . . . . . .9015A-20-107 Transmission control unit . . . . . . . . . . . .9020-20-3
Deutsch contact Electronic clutch calibration
Install . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-108 Transmission control unit . . . . . . . . . . . .9020-20-7
Diagnose Electronic fuel injection system
Drive Line Malfunctions. . . . . . . . . . . . .9020-15-28 operation. . . . . . . . . . . . . . . . . . . . . . . . .9010-05-4
Diagnose Engine Malfunctions . . . . . . . . . .9010-15-1 Engine
Diagnose malfunction Theory of operation. . . . . . . . . . . . . . . . .9010-05-1
Hydraulic system. . . . . . . . . . . . . . . . . .9025-15-15 Engine air heater circuit
Transmission system . . . . . . . . . . . . . . .9020-15-6 Theory of operation. . . . . . . . . . . . . . . . .9010-05-3
Diagnostic Touble Codes (DTCs) Engine air heater circuit operation . . . . . . .9010-05-2
CAN Monitor Unit (CMU). . . . . . . . . . . 9015B-20-6 Engine air heater harness (W7)
Engine Control Unit (ECU) . . . . . . . . 9015B-20-39 Component location . . 9015A-10-40, 9015B-10-52
Flex Load Controller (FLC) . . . . . . . . . 9015B-20-8 Wiring diagram . . . . . . . . . . . . . . . . . 9015B-10-54
Sealed Switch Module (SSM) . . . . . . 9015B-20-22 Engine control unit
Transmission Control Unit (TCU) . . . 9015B-20-26 Pressure sensors test . . . . . . . . . . . . 9015A-20-98
Diagnostic Trouble Codes Pressure solenoids test. . . . . . . . . . . 9015A-20-98
Service codes . . . . . . . . . . . . . . . . . . . 9015A-20-2 Speed sensors test . . . . . . . . . . . . . . 9015A-20-97
Diagnostic Trouble Codes (DTCs) Temperature sensors test . . . . . . . . . 9015A-20-96
Quick reference list . . . . . . . . . . . . . . . 9015B-20-1 Engine Control Unit (ECU)
Diagnostics Diagnostic Trouble Codes (DTCs). . . 9015B-20-39
Engine Malfunctions . . . . . . . . . . . . . . . .9010-15-1 Engine control unit (ECU)
Diagnostics menu Remove and install . . . . . . . . . . . . . . 9015B-20-80
Indx
Battery monitor (d 03) . . . . . . . . . . . . 9015A-15-25 Engine Control Unit (ECU) 3
Continuity check (d 02) . . . . . . . . . . . 9015A-15-22 Theory of operation. . . . . . . . . . . . . . . 9015B-15-5
Diagnostic trouble codes (d 01). . . . . 9015A-15-19 Engine Controller Unit Circuit
Differential Theory Of Operation . . . . . . . . . . . . . 9015A-15-77
Axle coolers . . . . . . . . . . . . . . . . . . . . .9020-05-15 Engine frame harness (W5)
Differential lock circuit Component location . . 9015A-10-36, 9015B-10-42
Pressure test. . . . . . . . . . . . . . . . . . . . .9020-25-17 Wiring diagram . . . . . . . . . . . . . . . . . 9015B-10-44
Differential lock solenoid valve Engine harness (W6
Remove and install . . . . . . . . . . . . . .9015A-20-129 Component location . . . . . . . . . . . . . 9015B-10-46
Differential/axle Engine harness (W6)
Diagnose malfunctions . . . . . . . . . . . . .9020-15-20 Component location . . . . . . . . . . . . . 9015A-10-38

092005
PN=3
Index
Page Page
Engine harness (W6 Functional schematic and component location

Wiring diagram . . . . . . . . . . . . . . . . . 9015B-10-50 Legend . . . . . . . . . . . . . . . . . . . . . . . . 9015B-10-4
Engine sensors (d 04) Fuse
Users diagnostics menu . . . . . . . . . . 9015A-15-26 Specification . . . . . . . . . . 9015A-10-1, 9015B-10-2
External service brake inpection . . . . . . . . .9020-20-1
G
F
Gauge ranges . . . . . . . . . . . . . . . . . . . 9015A-20-86
Fan drive operation . . . . . . . . . . . . . . . . .9025-05-13
Fan motor
Case drain test . . . . . . . . . . . . . . . . . . . .9025-25-7 H
Fan Motor
Speed test . . . . . . . . . . . . . . . . . . . . . . .9025-25-4 Heater system
Fan pump Diagnose malfunctions . . . . . . . . . . . . . .9031-15-5
Flow test . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-5 High pressure fuel pump solenoid 1
Fan pump pressure and RPM test Test . . . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-98
Hydraulic fan pressure test . . . . . . . . . . .9025-25-2 High pressure fuel pump solenoid 2
Fault code interpretation . . . . . . . . . . . . . 9015A-20-5 Test . . . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-98
Fault code verification check . . . . . . . . 9015B-20-63 Hydraulic
Fault codes mode (d 01) Braking system . . . . . . . . . . . . . . . . . . .9025-05-26
Diagnostics menu . . . . . . . . . . . . . . . 9015A-15-19 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-4
Filter Hydraulic Fan
Hyraulic. . . . . . . . . . . . . . . . . . . . . . . . .9025-05-66 Flow test . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-5
Flasher light signals Hydraulic fan motor
Chassis computer unit. . . . . . . . . . . . 9015A-15-51 Case drain test . . . . . . . . . . . . . . . . . . . .9025-25-7
FLC connector Hydraulic oil filter
Repair . . . . . . . . . . . . . . . . . . . . . . . . 9015B-20-77 Inspection procedure. . . . . . . . . . . . . . .9025-25-46
Flex Load Controller (FLC) Hydraulic oil filter base
Diagnostic Trouble Codes (DTCs). . . . 9015B-20-8 Return hydraulic filter . . . . . . . . . . . . . .9025-05-66
Fault exceptions . . . . . . . . . . . . . . . . 9015B-20-47 Hydraulic oil warm-up procedure . . . . . . . .9025-25-1
Flex load controller (FLC) Hydraulic pump
Remove and install . . . . . . . . . . . . . . 9015B-20-82 Flow test . . . . . . . . . . . . . . . . . . . . . . . .9025-25-15
Flex Load Controller (FLC) Hydraulic pump case drain
Theory of operation. . . . . . . . . . . . . . . 9015B-15-9 Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-17
Front console harness (W4) Hydraulic pump control
Component location . . 9015A-10-34, 9015B-10-38 Full flow . . . . . . . . . . . . . . . . . . . . . . . .9025-05-10
Wiring diagram . . . . . . . . . . . . . . . . . 9015B-10-40 Function bottomed . . . . . . . . . . . . . . . .9025-05-12
Fuel line leakage test . . . . . . . . . . . . . . . . .9010-25-1 Function metering . . . . . . . . . . . . . . . . . .9025-05-8
Fuel rail pressure sensor Neutral . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-6
Indx Test . . . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-98 Hydraulic pump magin
4 Fuel sensor (d 07) Adjustment test . . . . . . . . . . . . . . . . . . . .9025-25-9
Users diagnostic menu . . . . . . . . . . . 9015A-15-35 Hydraulic sensors (d 06)
Fuel temperature sensor Users diagnostics menu . . . . . . . . . . 9015A-15-32
Test . . . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-96 Hydraulic system
Functional Schematic Malfunctions . . . . . . . . . . . . . . . . . . . . .9025-15-15
Electrical . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-8 Hydraulic system schematic
Functional schematic Neutral . . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-2
Electrical . . . . . . . . . . . . . . . . . . . . . . 9015B-10-14 Hydraulics
Functional Schematic and Component Location Circuit symbols . . . . . . . . . . . . . . . . . . . .9025-15-1
Legend . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-3 Hydrometer test . . . . . . . 9015A-20-91, 9015B-20-52

092005
PN=4
Index
Page Page
J Accessing in montor . . . . . . . . . . . . . . 9015A-15-8

Normal display menu . . . . . . . . . . . . . 9015A-15-9
Job timer mode (A 04) Metri-Pack connector
Accessory menu . . . . . . . . . . . . . . . . 9015A-15-17 Replace . . . . . . . . . . 9015A-20-106, 9015B-20-67
Metric units mode (A 07)
Accessory menu . . . . . . . . . . . . . . . . 9015A-15-19
Modulation circuit
L
Transmission. . . . . . . . . . . . . . . . . . . . . .9020-05-9
Monitor
Leakage test
Accessory menu . . . . . . . . . . . . . . . . 9015A-15-11
Transmission element . . . . . . . . . . . . . .9020-25-13
Gauge ranges . . . . . . . . . . . . . . . . . . 9015A-20-86
Legend
Monitor display unit
Functional Schematic and Component
Accessing menus . . . . . . . . . . . . . . . . 9015A-15-8
Location. . . . . . . . . . . . . . . . . . . . . . 9015A-10-3
Normal display . . . . . . . . . . . . . . . . . . 9015A-15-9
Functional schematic and component
Service diagnostics menu . . . . . . . . . 9015A-15-41
location . . . . . . . . . . . . . . . . . . . . . . 9015B-10-4
Monitor display unit circuit
License plate light harness (W15)
Theory of operation. . . . . . . . . . . . . . . 9015A-15-4
Component location . . . . . . . . . . . . . 9015A-10-50
Monitor Display Unit Circuit
Load center harness (W3)
Theory Of Operation-Modes Of
Component location . . 9015A-10-23, 9015B-10-22
Operation . . . . . . . . . . . . . . . . . . . . 9015A-15-7
Wiring diagram . . . . . . . . . . . . . . . . . 9015B-10-24
Load sense circuit
Boom raise and bucket dump . . . . . . . .9025-05-59
Steering . . . . . . . . . . . . . . . . . . . . . . . .9025-05-55 O
Steering and boom down . . . . . . . . . . .9025-05-57
Load sense circuit-steering . . . . . . . . . . . .9025-05-55
Oil
Load sense relief valve
Transmission oil warm-up procedure. . . .9020-25-1
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-60
Oil clean-up
Load test, batteries. . . . . 9015A-20-92, 9015B-20-53
Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-20-1
Loader control valve . . . . . . . . . . . . . . . . .9025-05-40
Oil filter, hydraulic
Loader frame harness (W2)
Inspection procedure. . . . . . . . . . . . . . .9025-25-46
Component location . . 9015A-10-22, 9015B-10-18
Operation
Wiring diagram . . . . . . . . . . . . . . . . . 9015B-10-20
Park Brake . . . . . . . . . . . . . . . . . . . . . .9020-05-16
Loader hydraulic system. . . . . . . . . . . . . . .9025-05-1
Torque converter. . . . . . . . . . . . . . . . . . .9020-05-4
Component location . . . . . . . . . . . . . . . .9025-15-8
Transmission. . . . . . . . . . . . . . . . . . . . . .9020-05-4
Loader system relief valve
Operational tests
Pressure test. . . . . . . . . . . . . . . . . . . . .9025-25-19
Air filter restriction indicator switch . . . . .9010-25-4
Low standby pressure
Air intake system leakage . . . . . . . . . . . .9010-25-3
Adjustment test . . . . . . . . . . . . . . . . . . . .9025-25-9
Fuel line leakage. . . . . . . . . . . . . . . . . . .9010-25-1
Lube pressure test
Outlet section
Transmission. . . . . . . . . . . . . . . . . . . . .9020-25-15
Steering, loader in neutral . . . . . . . . . . .9025-05-53
Indx
5
M
P
Machine I.D. mode (d 10)
Users diagnostics mode . . . . . . . . . . 9015A-15-37 Park brake
Manifold air temperature sensor Diagnose malfunctions . . . . . . . . . . . . .9020-15-29
Test . . . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-96 Park Brake
Maximum system pressure Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-16
Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-12 Park brake
Menus Pressure test. . . . . . . . . . . . . . . . . . . . . .9020-25-2
Accessary menu . . . . . . . . . . . . . . . . 9015A-15-11 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-4

092005
PN=5
Index
Page Page
Pilot Control R
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-36
Pilot control accumulator Radio harness (W21)
Precharge test . . . . . . . . . . . . . . . . . . .9025-25-38 Component location . . . . . . . . . . . . . 9015B-10-76
Pilot control valve Wiring diagram . . . . . . . . . . . . . . . . . 9015B-10-78
Pressure test. . . . . . . . . . . . . . . . . . . . .9025-25-34 Radio harness (W34)
Pilot Controller Component location . . . . . . . . . . . . . 9015A-10-65
Boom Float . . . . . . . . . . . . . . . . . . . . . .9025-05-30 Rear frame harness (W13)
Pilot enable circuit . . . . . . . . . . . . . . . . . 9015B-15-9 Component location . . 9015A-10-48, 9015B-10-64
Pilot enable solenoid valve Wiring diagram . . . . . . . . . . . . . . . . . 9015B-10-66
Remove and install . . . . . . . . . . . . . .9015A-20-129 Reconfiguration
Pilot Enable/Boom Down Circuit electronic controller . . . . . . . . . . . . . . 9015B-20-87
Theory Of Operation . . . . . . . . . . . . . 9015A-15-71 reconfigure
Pilot orifice check valve reprogram
Control valve section. . . . . . . . . . . . . . .9025-05-38 controller
Pin disconnect
mdu . . . . . . . . . . . . . . . . . . . . . .9015A-20-125
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-30
Regulating circuit
Pin disconnect circuit . . . . . . . . . . . . . . . 9015B-15-9
Transmission control valve . . . . . . . . . . .9020-05-9
Pin disconnect harness (W16)
Relay locations . . . . . . . . . . . . . . . . . . . . 9015A-10-1
Component location . . . . . . . . . . . . . 9015A-10-52
Relief
Power train
Load sense . . . . . . . . . . . . . . . . . . . . . .9025-05-60
Component location . . . . . . . . . . . . . . . .9020-15-4
Relief pressure
Components . . . . . . . . . . . . . . . . . . . . . .9020-05-2
Convertor . . . . . . . . . . . . . . . . . . . . . . .9020-25-24
Power train component location . . . . . . . . .9020-15-4
Relief valve
Power train components . . . . . . . . . . . . . . .9020-05-2
Pressure test. . . . . . . . . . . . . . . . . . . . .9025-25-19
Precharge test
Relief valve operation . . . . . . . . . . . . . . . .9025-05-61
Pilot control accumulator. . . . . . . . . . . .9025-25-38
Return to carry
Pressure Reducing
Valve . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-19 Height kickout adjustment . . . . . . . . 9015A-20-101,
Pressure reducing valve 9025-20-2
Boom down-engine off . . . . . . . . . . . . .9025-05-23 Return To Carry Theory of Operation . . 9015A-15-73
Boom raise operation . . . . . . . . . . . . . .9025-05-19 Return To Dig Circuit Theory of
Boom rown-rngine running operation . .9025-05-21 Operation . . . . . . . . . . . . . . . . . . . . . 9015A-15-73
Theory of operation. . . . . . . . . . . . . . . .9025-05-25 Return-to-carry
Pressure switches Adjustment . . . . . . . . . . . . . . . . . . . . 9015B-20-61
Remove and install . . 9015A-20-128, 9015B-20-66 Return-to-carry (RTC) circuit. . . . . . . . . . 9015B-15-9
Pressure test Return-to-dig circuit . . . . . . . . . . . . . . . . 9015B-15-9
Differential lock . . . . . . . . . . . . . . . . . . .9020-25-17 Adjustment . . . . . . . . 9015A-20-102, 9015B-20-62,
Park brake . . . . . . . . . . . . . . . . . . . . . . .9020-25-2 9025-20-2
PRV Return-to-dig harness (W8)
Pressure reducing valve . . . . . . . . . . . .9025-05-25 Component location . . . . . . . . . . . . . 9015A-10-42
Pump Reverse fan circuit . . . . . . . . . . . . . . . . . 9015B-15-9
Indx Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . .9025-05-4 Ride control accumulator
6 Discharge . . . . . . . . . . . . . . . . . . . . . . . .9025-20-3
Pump control assembly . . . . . . . . . . . . . . .9025-05-5
Pump, transmission Ride control circuit . . . . . . . . . . . . . . . . . 9015B-15-9
Pump flow test . . . . . . . . . . . . . . . . . . . .9020-25-6 Ride Control Circuit
Functional Schematic . . . . . . . . . . . . . 9015A-15-2
Theory Of Operation . . . . . . . . . . . . . . 9015A-15-2
Ride control harness
Q Component location . . 9015A-10-44, 9015B-10-56,
9015B-10-58
Quick shift mode (A 02) Roads
Accessory menu . . . . . . . . . . . . . . . . 9015A-15-13 Operating or traveling . . . . . . . . . . . . . .9000-01-11

092005
PN=6
Index
Page Page
ROPS Sensor, analog throttle position

Inpsect . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-12 Adjustment . . . . . . . . . . . . . . . . . . . . 9015A-20-99
Maintain . . . . . . . . . . . . . . . . . . . . . . . .9000-01-12 Service brake inspection, external . . . . . . .9020-20-1
Rotary beacon light circuit . . . . . . . . . . . 9015B-15-9 Service diagnostics menu
Monitor display unit . . . . . . . . . . . . . . 9015A-15-41
Solenoid test
Engine control unit pressure . . . . . . . 9015A-20-98
S High pressure fuel pump solenoid
1 . . . . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-98
Safety High pressure fuel pump solenoid
Add cab guarding for special uses . . . . .9000-01-3 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 9015A-20-98
Avoid unauthorized machine Solenoids activated
modifications . . . . . . . . . . . . . . . . . . . .9000-01-2 Transmission clutch engagement . . . . . .9020-05-1
Follow safety instructions . . . . . . . . . . . .9000-01-1 Specification
Inspect machine . . . . . . . . . . . . . . . . . . .9000-01-3 Fuse . . . . . . . . . . . . . . . . 9015A-10-1, 9015B-10-2
Operate only if qualified . . . . . . . . . . . . .9000-01-2 Specifications
Recognize safety information . . . . . . . . .9000-01-1 Electrical components . . . . . . . . . . . . 9015A-20-81,
Stay clear of moving parts . . . . . . . . . . .9000-01-3 9015B-20-54
Wear protective equipment . . . . . . . . . . .9000-01-2 speed sensor
Schematic continuity check
Information . . . . . . . . . . . 9015A-05-2, 9015B-05-2 three wire . . . . . . . . . . . . . . . . . . .9015A-20-105
Schematic Section, System Functional Spin control circuit . . . . . . . . . . . . . . . . . 9015B-15-9
Legend . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-2 Spin Control Circuit
Sealed Switch Module (SSM) Theory Of Operation . . . . . . . . . . . . . 9015A-15-54
Diagnostic Trouble Codes (DTCs). . . 9015B-20-22 Spin Control Harness (W14)
Sealed switch module (SSM) Component Location . . . . . . . . . . . . . 9015A-10-49
Remove and install . . . . . . . . . . . . . . 9015B-20-84 Spin control mode (d 09)
Secondary steering circuit . . . . . . . . . . . 9015B-15-9 Users diagnostics menu . . . . . . . . . . 9015A-15-36
Secondary Steering Circuit spped sensor
Theory Of Operation . . . . . . . . . . . . . 9015A-15-75 continuity check
Secondary steering inlet manifold two wire sensor . . . . . . . . . . . . . . .9015A-20-104
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-17 Stall speed test
Secondary steering manifold Torque converter. . . . . . . . . . . . . . . . . .9020-25-29
Primary check valve leakage test . . . . .9025-25-31 Start circuit
Secondary steering pump Theory Of Operation . . . . . . . . . . . . . . 9015A-15-1
Relief valve pressure test . . . . . . . . . . .9025-25-29 Starting circuit
Secondary Steering Pump Motor Harness (W23) Theory of operation. . . . . . . . . . . . . . . 9015B-15-1
Component Location . . . . . . . . . . . . . 9015A-10-62 Steering
Secondary steering switch harness (W17) Valve operation . . . . . . . . . . . . . . . . . . .9025-05-15
Component location . . . . . . . . . . . . . 9015A-10-54 Steering system components . . . . . . . . . .9025-05-14
Secondary steering system Steering valve
Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-18 Drift test . . . . . . . . . . . . . . . . . . . . . . . .9025-25-27
Indx
Sensor Circuit Neutral leakage test . . . . . . . . . . . . . . .9025-25-25 7
Check . . . . . . . . . . . . . . . . . . . . . . . . 9015B-20-63 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-15
Sensor test Stop watch mode (A 05)
Camshaft sensor. . . . . . . . . . . . . . . . 9015A-20-97 Accessory menu . . . . . . . . . . . . . . . . 9015A-15-17
Crankshaft sensor . . . . . . . . . . . . . . . 9015A-20-97 Switches, pressure
Engine control unit pressure . . . . . . . 9015A-20-98 Remove and install . . 9015A-20-128, 9015B-20-66
Engine control unit speed . . . . . . . . . 9015A-20-97 System Functional Schematic
Engine control unit temperature . . . . 9015A-20-96 Electrical . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-8
Fuel rail pressure . . . . . . . . . . . . . . . 9015A-20-98 System functional schematic
Fuel temperature. . . . . . . . . . . . . . . . 9015A-20-96 Electrical . . . . . . . . . . . . . . . . . . . . . . 9015B-10-14
Manifold air temperature . . . . . . . . . . 9015A-20-96 Information . . . . . . . . . . . 9015A-05-2, 9015B-05-2

092005
PN=7
Index
Page Page
System Functional Schematic Section Shift ranges in automatic mode. . . . . 9015A-15-62

Legend . . . . . . . . . . . . . . . . . . . . . . . . 9015A-10-2 System pressure test . . . . . . . . . . . . . . .9020-25-8
Thermal bypass vave pressure test. . . .9020-25-32
Transmission clutch calibration . . . . . . . . . .9020-20-7
Transmission clutch engagement
T Solenoids activated . . . . . . . . . . . . . . . . .9020-05-1
Transmission control circuit
Tail light signals . . . . . . . . . . . . . . . . . . 9015A-15-51 First forward . . . . . . . . . . . . . . . . . . . . . .9020-15-2
Test Transmission control unit
Cycle time. . . . . . . . . . . . . . . . . . . . . . .9025-25-35 Functions set at monitor display
Maximum system pressure . . . . . . . . . .9025-25-12 unit . . . . . . . . . . . . . . . . . . . . . . . . 9015A-15-59
Theory of operation Transmission Control Unit Circuit
CAN monitor unit (CMU) . . . . . . . . . . 9015B-15-32 Theory Of Operation . . . . . . . . . . . . . 9015A-15-56
Charging circuit . . . . . . . . . . . . . . . . . . 9015B-15-1 Transmission Control Unit (TCU)
Controller Area Network (CAN) . . . . . . 9015B-15-3 Diagnostic Trouble Codes (DTCs). . . 9015B-20-26
Electronic fuel injection system . . . . . . . .9010-05-4 Transmission control unit (TCU)
Engine air heater circuit . . . .9010-05-2, 9010-05-3 Remove and install . . . . . . . . . . . . . . 9015B-20-83
Engine Control Unit (ECU) . . . . . . . . . 9015B-15-5 Transmission Control Unit (TCU)
Flex Load Controller (FLC) . . . . . . . . . 9015B-15-9 Theory of operation. . . . . . . . . . . . . . 9015B-15-27
Pilot Control . . . . . . . . . . . . . . . . . . . . .9025-05-36 Transmission control valve
Theory Of Operation Components . . . . . . . . . . . . . . . . . . . . . .9020-05-9
Pilot Enable/Boom Down Circuit . . . . 9015A-15-71 Regulating circuit . . . . . . . . . . . . . . . . . .9020-05-9
Theory of operation Transmission control valve connector body
Pressure reducing valve . . . . . . . . . . . .9025-05-25 Remove and install . . . . . . . . . . . . . .9015A-20-111
Theory Of Operation Transmission control valve connector contact
Secondary Steering Circuit . . . . . . . . 9015A-15-75 Install . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-112
Theory of operation Transmission Control Valve Solenoid
Starting circuit . . . . . . . . . . . . . . . . . . . 9015B-15-1 Check . . . . . . . . . . . . . 9015A-20-93, 9015B-20-59
Transmission Control Unit (TCU) . . . 9015B-15-27 Transmission controll
Thermal bypass valve Clutch adjustment . . . . . . . . . . . . . . . . . .9020-20-3
Temperature test. . . . . . . . . . . . . . . . . .9020-25-30 Transmission controller
Throttle position sensor Clutch calibration . . . . . . . . . . . . . . . . . .9020-20-7
Adjustment . . . . . . . . . . . . . . . . . . . . 9015A-20-99 Transmission Controller Unit
Torque converter Response to Malfunctions . . . . . . . . . 9015A-15-65
Converter-in pressure test. . . . . . . . . . .9020-25-19 Transmission harness (W10)
Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-4 Component location . . 9015A-10-46, 9015B-10-60
Torque converter stall speed test . . . . . . .9020-25-29 Wiring diagram . . . . . . . . . . . . . . . . . 9015B-10-62
Tranmission Transmission oil cooler
Modulation circuit . . . . . . . . . . . . . . . . . .9020-05-9 Bypass valve pressure test . . . . . . . . . .9020-25-32
Tranmssion Restriction test . . . . . . . . . . . . . . . . . . .9020-25-34
Clutch modulation . . . . . . . . . . . . . . . . .9020-05-12 Thermal bypass valve temperature
Transmission test . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-30
Indx Clutch pressure test . . . . . . . . . . . . . . .9020-25-10 Transmission Operation
8
Converter out flow test . . . . . . . . . . . . .9020-25-26 1st Gear Forward . . . . . . . . . . . . . . . . . .9020-05-6
Converter relief pressure test . . . . . . . .9020-25-24 Transmission pump flow test . . . . . . . . . . .9020-25-6
Converter-in pressure test. . . . . . . . . . .9020-25-19 Transmission sensors (d 05)
Converter-out pressure test. . . . . . . . . .9020-25-21 Users diagnostics menu . . . . . . . . . . 9015A-15-30
Element leakage test . . . . . . . . . . . . . .9020-25-13 Transmission system
Flow test . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-6 Pressure test. . . . . . . . . . . . . . . . . . . . . .9020-25-8
Lube pressure test . . . . . . . . . . . . . . . .9020-25-15 Transmission warm-up procedure. . . . . . . .9020-25-1
Modes of operation . . . . . . . . . . . . . . 9015A-15-58 Traveling
Oil cooler restriction test . . . . . . . . . . . .9020-25-34 On public roads. . . . . . . . . . . . . . . . . . .9000-01-11
Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-4 Turbocharger boost pressure test . . . . . . . .9010-25-4

092005
PN=8
Index
Page
Turn and flasher light signals

Chassis computer unit. . . . . . . . . . . . 9015A-15-51
Turn signal light circuit . . . . . . . . . . . . . . 9015B-15-9
Users diagnostics menu

Engine sensors (d 04). . . . . . . . . . . . 9015A-15-26
Fuel sensor (d 07) . . . . . . . . . . . . . . 9015A-15-35
Hydraulic sensors (d 06) . . . . . . . . . . 9015A-15-32
Machine I.D. mode (d 10) . . . . . . . . . 9015A-15-37
Spin control mode (d 09). . . . . . . . . . 9015A-15-36
Transmission sensors (d 05) . . . . . . . 9015A-15-30
Valve
Anti-Cavitation
Operation . . . . . . . . . . . . . . . . . . . . .9025-05-65
Brake . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-28
Load sense relief operation. . . . . . . . . .9025-05-60
Loader control. . . . . . . . . . . . . . . . . . . .9025-05-40
Pressure Reducing . . . . . . . . . . . . . . . .9025-05-19
Valve, boom down solenoid
Remove and install . . . . . . . . . . . . . .9015A-20-129
Valve, differential lock solenoid
Valve, pilot enable solenoid
Warm-up procedure
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . .9025-25-1
Washer pump circuit. . . . . . . . . . . . . . . . 9015B-15-9
Weather Pack contact
Install . . . . . . . . . . . . . . . . . . . . . . . .9015A-20-110
Wiper circuit signals Indx
Chassis computer unit. . . . . . . . . . . . 9015A-15-51 9
Wiper motor circuit . . . . . . . . . . . . . . . . . 9015B-15-9
Wiring diagram
Information . . . . . . . . . . . 9015A-05-2, 9015B-05-2
Work light circuit. . . . . . . . . . . . . . . . . . . 9015B-15-9
Work lights signals . . . . . . . . . . . . . . . . 9015A-15-51
1st Gear Forward
Transmission Operation . . . . . . . . . . . . .9020-05-6
4-way flasher circuit . . . . . . . . . . . . . . . . 9015B-15-9

092005
PN=9
Index
Indx
10

092005
PN=10

TM2075 - Tecnico Operacion y Prueba 644J-724J

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644J and 724J

For complete service information also see:

This manual is written for an experienced technician.

Live with safety: Read the safety messages in the

This is the safety-alert symbol. When you see this

Technical manuals are divided in two parts: repair and

Information is organized in groups for the various

Technical Manuals are concise guides for specific

Fundamental service information is available from other

TM2075 (03MAR05) 644J and 724J Loader

Technical Information Feedback Form

We need your help to continually improve our technical

SEND TO: John Deere Dubuque Works

FAX NUMBER: 563-589-5800

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TM2075 (03MAR05) 644J and 724J Loader

TM2075 (03MAR05) 644J and 724J Loader

SECTION 9005—Operational Checkout Procedure

SECTION 9015B—Electrical System—644J And

SECTION 9020—Power Train

SECTION 9025—Hydraulic System

SECTION 9031—Heating And A/C

All information, illustrations and specifications in this manual are based on

TM2075 (03MAR05) i 644J and 724J Loader

TM2075 (03MAR05) ii 644J and 724J Loader

Group 01—Safety Information

TM2075 (03MAR05) 9000-1 644J and 724J Loader

TM2075 (03MAR05) 9000-2 644J and 724J Loader

This is the safety alert symbol. When you see this

Follow the precautions and safe operating practices

A signal word — DANGER, WARNING, or CAUTION — is

Follow Safety Instructions

Read the safety messages in this manual and on the

Be sure all operators of this machine understand every

TM2075 (03MAR05) 9000-01-1 644J and 724J Loader

Wear Protective Equipment

Guard against injury from flying pieces of metal or debris;

Wear close fitting clothing and safety equipment

Avoid Unauthorized Machine Modifications

TM2075 (03MAR05) 9000-01-2 644J and 724J Loader

Special work situations or machine attachments may

Use load-clamping grapples to keep bulky loads from

Inspect machine carefully each day by walking around it

Keep all guards and shields in good condition and

Stay Clear Of Moving Parts

Stop engine before examining, adjusting or maintaining

Keep guards and shields in place. Replace any guard or

TM2075 (03MAR05) 9000-01-3 644J and 724J Loader

This machine uses a high-pressure hydraulic system.

Never search for leaks with your hands. Protect hands.

If hydraulic fluid penetrates your skin, see a doctor

Beware Of Exhaust Fumes

Prevent asphyxiation. Engine exhaust fumes can cause

TM2075 (03MAR05) 9000-01-4 644J and 724J Loader

Keep A Fire Extinguisher Available: Always keep a

Prevent Battery Explosions

Battery gas can explode. Keep sparks, lighted matches,