TM 11446

329D and 333D Skid Steer
Loader (Manual Controls)

Diagnostic
OPERATION AND TEST MANUAL
Manual Controls models 329D, 333D

TM11446 01 DEC 15 (ENGLISH)
For complete service information also see:

326D, 328D, 329D, 332D and 333D Skid Steer Loader (Manual Controls)
TM11431
Repair
Super Caddy Oil Cleanup Procedure CTM310
120 Series Hydraulic Cylinders CTM120519
120 Series Hydraulic Cylinders CTM114319
PowerTech E 2.4L & 3.0L Diesel Engines CTM101019
COOLANT HEATER SERVICE MANUAL CTM10090X19
John Deere Commercial Worksite Products

Pinted by Belgreen
TM11446-OPERATION AND TEST MANUAL (g) by Belgreen v2.5
Table of contents
FOREWORD
TECHNICAL INFORMATION FEEDBACK FORM
Section 9000 - GENERAL INFORMATION
Group 01 - Safety
Section 9001 - DIAGNOSTIC TROUBLE CODES (DTCS)
Group 10 - Engine Control Unit (ECU) Diagnostic Trouble Codes
Group 20 - Engagement and Monitor Unit (EMU) Diagnostic Trouble Codes
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10 - Operational Checkout Procedure
Section 9010 - ENGINE
Group 05 - Theory of Operation
Group 15 - Diagnostic Information
Group 25 - Tests
Section 9015 - ELECTRICAL SYSTEM
Group 05 - System Information
Group 10 - System Diagrams
Group 15 - Sub-System Diagnostics
Group 16 - Monitor Operation
Group 20 - References
Section 9020 - POWER TRAIN
Group 25 - Tests
Section 9025 - HYDRAULIC SYSTEM
Group 25 - Tests
Section 9026 - HYDROSTATIC SYSTEM
Group 25 - Tests
Section 9031 - HEATING AND AIR CONDITIONING
Group 25 - Tests
Section 9900 - DEALER FABRICATED TOOLS
Group 99 - Dealer Fabricated Tools
<- Go to Global Table of contents TM11446-OPERATION AND TEST MANUAL

Foreword
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified
in this manual and are recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text
of the manual.
CAUTION:
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for
personal injury.
Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.
Operation and tests sections help you identify the majority of routine failures quickly.
Information is organized in groups for the various components requiring service instruction. At the beginning of each group are
summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service
parts kits, specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information
needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of operation, fundamentals of
troubleshooting, general maintenance, and basic type of failures and their causes.

GENERAL INFORMATION (g) by Belgreen v2.0
Technical Information Feedback Form

We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments,
ideas and improvements.
Technical Manual Fax
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18600 South John Deere Road
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<- Go to Section TOC Section 9000 page 1 TM11446-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION

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

Section 9000 - GENERAL INFORMATION Group 01: Safety
Group 01 - Safety
Recognize Safety Information
Safety Alert Symbols
Safety Alert Symbols
This is the safety alert symbol. When this symbol is noticed on the machine or in this manual, be alert for the
potential of personal injury.
Follow the precautions and safe operating practices highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious
hazards.
On the machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and
WARNING signs are located near specific hazards. General precautions are on CAUTION labels.
Follow Safety Instructions
Safety Messages
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition.
Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety
signs. Replacement safety signs are available from your John Deere dealer.
There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in
this operator′s manual.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or
safety and affect machine life.
If you do not understand any part of this manual and need assistance, contact your John Deere dealer.
Operate Only If Qualified

Do not operate this machine unless the operator′s manual has been read carefully, and you have been qualified by supervised
training and instruction.
Operator should be familiar with the job site and surroundings before operating. Try all controls and machine functions with the
machine in an open area before starting to work.
Know and observe all safety rules that may apply to every work situation and work site.
Wear Protective Clothing
Protective Clothing
Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud
noises.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating
machine.
Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute
genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or
hazardous performance. Non-John Deere parts, or any damage or malfunctions resulting from their use, are not covered by any
John Deere warranty.
Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability,
and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the
electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or
its performance.
Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of
the machine, or that alter machine controls, performance, or reliability.
Inspect Machine
Inspect Machine
Inspect machine carefully each day by walking around it before starting.

Inspect and Clean the Polycarbonate Windows. See Inspect and Clean Polycarbonate Windows. (Section 4-1.)
Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts
immediately. Pay special attention to hydraulic hoses and electrical wiring.
Stay Clear of Moving Parts
Stay Clear Of Moving Parts
Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintaining any part of machine with moving parts.
Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is
complete.
Avoid High-Pressure Fluids
High Pressure
Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion,
exposed wire braid or any other signs of wear or damage.
Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying
pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours
or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such
information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling
1-800-822-8262 or +1 309-748-5636.
Avoid High-Pressure Oils
Avoid High Pressure Oils
Avoid High-Pressure Oils
This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.
Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop
engine and relieve pressure before disconnecting lines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within
hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in
Moline, Illinois, U.S.A.
Work In Ventilated Area
Engine exhaust fumes
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust
fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors and get outside air into the area.
Prevent Fires
Handle Fuel Safely
Clean Machine Regularly
Carry A Fire Extinguisher
Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks
or flame.
Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines,
hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine
compartment.
Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine
electrical wiring and connectors frequently for damage.
Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use
extinguisher properly.
Prevent Battery Explosions
Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Handle Chemical Products Safely
Material Safety Data Sheet
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere
equipment include such items as lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety
procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and
how to do the job safely. Then follow procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)
Decommissioning: Proper Recycling and Disposal of Fluids and

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

Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Clean Debris from Machine
Clean Debris From Machine
Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator′s station clean and
free of debris.
Clean any oil spills or fuel spills on machine surfaces.
Temperature in engine compartment may go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS
PERIOD.
Open access door(s) to cool the engine faster, and clean engine compartment.
Use Steps and Handholds Correctly
Use Handholds and Steps
Prevent falls by facing the machine when getting on and off. Maintain 3-point contact with steps and handrails. Never use
machine controls as handholds.
Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never
jump when exiting machine. Never mount or dismount a moving machine.
Start Only From Operator′s Seat
Operate Only From Operators Seat
Avoid unexpected machine movement. Start engine only while sitting in operator′s seat. Ensure all controls and working tools
are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid
terminals.
Use and Maintain Seat Belt
Use and Maintain Seat Belt
Use seat belt when operating machine . Remember to fasten seat belt when loading and unloading from trucks and during
other uses.
Examine seat belt frequently. Be sure 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 3 years, regardless of appearance.
Prevent Unintended Machine Movement

LEGEND:
1 Park Brake Switch
Park Brake Switch
Be careful not to accidentally actuate controls. Follow these steps during work interruptions, before allowing coworkers to
approach the machine, before standing up, leaving the operator′s seat, or exiting the machine:
Lower equipment to the ground

Press park brake switch (1) to position P to engage park brake
Stop the engine
Raise interlocking seat bar
Avoid Work Site Hazards
Contact with electrical lines
Operate on Solid Footing
Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all
underground utilities before starting work.
Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris
that could move unexpectedly if run over.
Avoid boom or attachment contact with overhead obstacles or overhead electrical lines. Never move machine closer
than 3 m (10 ft) plus twice the line insulator length to overhead wires.
Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid
swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal person to keep vehicles
and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep
signal person in view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or
excavations.
Avoid working under over-hanging embankments or stockpiles that could collapse under or on machine.
Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow
removal or clearing mud, dirt, etc.). At high speeds hitting obstacles (rocks, uneven concrete or manholes) can cause a sudden
stop. Always wear your seat belt. On units equipped with shoulder belts always wear both the seat and shoulder belt and do
not lean forward while operating.
Do not stand on track.
Keep Riders Off Machine
Keep Riders Off Machine
Only allow operator on machine.

Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects.
Riders may obstruct operator’s view or impair their ability to operate machine safely.
Avoid Backover Accidents
Avoid Backover Accidents
Before moving machine, be sure that all persons or vehicles are clear of machine path. Turn around and look directly
for best visibility. Keep windows clean.
Be certain reverse warning alarm is working properly (if equipped).
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.
Avoid Machine Tip Over
Use Seat Belt
Avoid Machine Tip Over
Use seat belt at all times.

Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you.
Load and unload from trucks or trailers carefully. Be sure that 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 wet, soft, rocky, or frozen ground.
Know the capacity of the machine. Do not overload. Be careful with heavy loads. Using oversize buckets or lifting heavy
objects reduces machine stability.
Ensure solid footing. Use extra care in soft ground conditions or on structures that may not uniformly support the tracks
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.
Operating On Slopes
Operating On Slopes-Tracked
Avoid side slope travel whenever possible. When working on steep slopes, travel as straight up and down as possible and keep
the heavy end of the vehicle uphill to prevent machine tip over.
Carry the load as low as possible for maximum stability and visibility.
Select low speed before starting down slope. The slope on which you can operate safely will be limited by ground condition and
the load being handled.
Be alert to wind direction and velocity.
Operating Or Traveling On Public Roads
Operating or Traveling On Public Roads
Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lighting and markings to
assure they are visible to other drivers.
Install additional lights, beacons, slow moving vehicle (SMV) emblems, or other devices and use as required to make the
machine visible and identify it as a work machine. Check state and local regulations to assure compliance. Keep these devices
clean and in working condition.
Inspect and Maintain ROPS

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

Check hardware torque.
Check isolation mounts for damage, looseness or wear; replace them if necessary.
Check ROPS for cracks or physical damage.
Add and Operate Attachments Safely

Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect
machine stability or reliability, and may create a hazard for others near the machine.
Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or
recommended. Verify that all connections are secure and attachment responds properly to controls.
Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions,
carefully operate attachment to learn its characteristics and range of motion.
Park and Prepare for Service Safely
Do Not Operate Tag
Support Machine Properly
Warn others of service work. Always park and prepare machine for service or repair properly.
Park machine on a level surface and lower equipment to the ground.

Engage park brake.
Stop engine and remove key.
Attach a “DO NOT OPERATE” tag in an obvious place in the operator′s station.
Securely support machine or attachment before working under it.
Do not support machine with any hydraulically actuated tools or attachments.

Do not support machine with cinder blocks or wooden pieces that may crumble or crush.
Do not support machine with a single jack or other devices that may slip out of place.
Always install boom lock before working on or around this machine with the loader boom raised.
Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the
engine must be running for service work.
Service Cooling System Safely
Cooling System
Explosive release of fluids from pressurized cooling system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve
pressure before removing completely.
Remove Paint Before Welding or Heating
Toxic Fumes
Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an
approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper
containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or
heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.
Make Welding Repairs Safely
Avoid Heating Near Pressurized Fluid Lines
IMPORTANT:
Disable electrical power before welding. Turn off main battery switch or disconnect positive battery
cable. Separate harness connectors to engine and vehicle microprocessors.
Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines
fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure
there is good ventilation. Wear eye protection and protective equipment when welding.
Drive Metal Pins Safely
DIAGNOSTIC TROUBLE CODES (DTCS) (g) by Belgreen v2.0
Hardened Metal Parts
Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering
hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and object to prevent chipping.
Handle Cab Door Safely

LEGEND:
1 Cab Door
Cab Door
When servicing machine, be aware that cab door (1) is breakable.

Keep door closed if cab needs to be raised for service. Be aware of surroundings so that door does not come in contact with
any objects.
Use care if cab door needs to be removed. To prevent damage to the door, handle with care and store in a secure location.
Section 9001 - DIAGNOSTIC TROUBLE CODES (DTCS)

Table of contents
Group 10 - Engine Control Unit (ECU) Diagnostic Trouble Codes .................................................... 1
Engine Control Unit (ECU) Diagnostic Trouble Codes ........................................................................... 1
Foot Throttle Sensor Out of Range High Diagnostic Procedure ............................................................ 2
Foot Throttle Sensor Out of Range Low Diagnostic Procedure ............................................................. 2
000029.14 - Foot Throttle Sensor (Out of Range High) ........................................................................ 3
Hand Throttle Sensor Out of Range High Diagnostic Procedure ........................................................... 4
Hand Throttle Sensor Out of Range Low Diagnostic Procedure ............................................................ 4
000091.14 - Hand Throttle Sensor (Out of Range High) ....................................................................... 5
000100.03 - Engine Oil Pressure High .................................................................................................. 5
Engine Air Filter Switch Data Above Normal Diagnostic Procedure ...................................................... 6
Ambient Air Temperature Out of Range High Diagnostic Procedure .................................................... 7
Ambient Air Temperature Out of Range Low Diagnostic Procedure ..................................................... 8
000237.13 - Vehicle Identification Number .......................................................................................... 8
Fan Coil Output Driver Out of Range Low Diagnostic Procedure ........................................................ 10
Fan Coil Output Driver Out of Range High Diagnostic Procedure ....................................................... 11
Manual Purge Mode Switch Active Too Long Diagnostic Procedure .................................................... 13
Fan Coil Output Driver Unknown Fault Diagnostic Procedure ............................................................. 14
Glow Plug Relay Output Out of Range Low Diagnostic Procedure ...................................................... 15
Glow Plug Relay Output Out of Range High Diagnostic Procedure ..................................................... 16
001110.31 - Engine Protection Has Shut Down Engine ...................................................................... 17
Starter Relay Output Out of Range Low Diagnostic Procedure ........................................................... 18
Starter Relay Output Out of Range Low Diagnostic Procedure ........................................................... 20
001321.16 - Starter Relay Output Moderately High Value .................................................................. 21
Hydraulic Oil Temperature Data Above Normal Diagnostic Procedure ............................................... 21
Hydraulic Oil Temperature Out of Range High Diagnostic Procedure ................................................. 21
Hydraulic Oil Temperature Out of Range Low Diagnostic Procedure .................................................. 22
Hydraulic Filter Restriction Switch Data Above Normal Diagnostic Procedure ................................... 24
No EMU Data on CAN Bus Abnormal Data Range Diagnostic Procedure ............................................. 25
Fan Reversing Coil Output Out of Range Low Diagnostic Procedure .................................................. 26
Fan Reversing Coil Output Out of Range High Diagnostic Procedure ................................................. 28
Group 20 - Engagement and Monitor Unit (EMU) Diagnostic Trouble Codes ............................... 30
Engagement and Monitor Unit (EMU) Diagnostic Trouble Codes ........................................................ 30
Park Brake Release Input Erratic or Bad Data Diagnostic Procedure .................................................. 31
Park Brake Release Input Out of Range Low Diagnostic Procedure .................................................... 33
Fuel Level Sensor Out of Range High Diagnostic Procedure ............................................................... 35
Fuel Level Sensor Out of Range Low Diagnostic Procedure ................................................................ 37
System Voltage Data Above Normal Diagnostic Procedure ................................................................ 38
System Voltage Data Below Normal Diagnostic Procedure ................................................................ 39
Switch Input Low Diagnostic Procedure—EH Control Machines .......................................................... 41
Alarm Output Out of Range Low Diagnostic Procedure ...................................................................... 44
Alarm Output Out of Range High Diagnostic Procedure ..................................................................... 46
Anti Theft Unknown Fault Diagnostic Procedure ................................................................................. 47
Seat Switch Input Out of Range Low Diagnostic Procedure ................................................................ 48
AC Compressor Clutch Output Out of Range Low Diagnostic Procedure ............................................ 50
AC Compressor Clutch Output Out of Range High Diagnostic Procedure ........................................... 52
No ECU Data on CAN Bus Abnormal Data Range Diagnostic Procedure ............................................. 53
No HCU Data on CAN Bus Abnormal Data Range Diagnostic Procedure ............................................. 53
Seat Switch Input Out of Range Low Diagnostic Procedure ................................................................ 55
Sensor Supply Voltage High Diagnostic Procedure—EH Control Machines ......................................... 57
Sensor Supply Voltage Low Diagnostic Procedure—EH Control Machines .......................................... 59

Over Ride Switch Input Out of Range Low Diagnostic Procedure ....................................................... 61
Switch Input Low Diagnostic Procedure—EH Control Machines .......................................................... 63
Park Brake Release Output Out of Range Low Diagnostic Procedure ................................................. 66
Park Brake Release Output Out of Range High Diagnostic Procedure ................................................ 68
Park Brake Release Input Erratic or Bad Data Diagnostic Procedure .................................................. 70
Park Brake Release Input Out of Range Low Diagnostic Procedure .................................................... 72
High Flow Driver Out of Range Low Diagnostic Procedure ................................................................. 74
High Flow Driver Out of Range High Diagnostic Procedure ................................................................ 76
VSF Purge Switch Input Out of Range Low Diagnostic Procedure ....................................................... 78
VSF Purge Switch Input Out of Range Low Diagnostic Procedure ....................................................... 80
Creep Mode Switch Input Out of Range Low Diagnostic Procedure .................................................... 82
Lap Bar Switch Input Out of Range Low Diagnostic Procedure ........................................................... 84
Hydraulic Valve Power 3 Out of Range High Diagnostic Procedure—EH Control Machines ................ 86
Propel Valve Power 2 to HCU Out of Range High Diagnostic Procedure ............................................. 89
Hydraulic Valve Power 1 Out of Range High Diagnostic Procedure—EH Control Machines ................ 91
Aux Hyd Channel 1 Input High Diagnostic Procedure—EH Control Machines ..................................... 94
Aux Hyd Channel 1 Input Low Diagnostic Procedure—EH Control Machines ...................................... 96
Aux Hyd Channel 2 Input High Diagnostic Procedure—EH Control Machines ..................................... 98
Aux Hyd Channel 2 Input Low Diagnostic Procedure—EH Control Machines .................................... 100
Aux Hyd Channel 2 Input Device Fault Diagnostic Procedure ........................................................... 101
High Flow Switch Input Out of Range Low Diagnostic Procedure ...................................................... 102
Two Speed Output Out of Range Low Diagnostic Procedure ............................................................ 103
Two Speed Output Out of Range High Diagnostic Procedure ........................................................... 104
Aux Hyd Extend Output Out of Range Low Diagnostic Procedure .................................................... 106
Aux Hyd Extend Output Out of Range High Diagnostic Procedure ................................................... 108
Aux Hyd Retract Output Out of Range Low Diagnostic Procedure .................................................... 111
Aux Hyd Retract Output Out of Range High Diagnostic Procedure ................................................... 113
Remote Start Input Out of Range Low Diagnostic Procedure ........................................................... 115
Checksum Error Unknown Fault Diagnostic Procedure ..................................................................... 115

Section 9001 - DIAGNOSTIC TROUBLE CODES (DTCS) Group 10: Engine Control Unit (ECU) Diagnostic Trouble Codes
Group 10 - Engine Control Unit (ECU) Diagnostic Trouble Codes

Engine Control Unit (ECU) Diagnostic Trouble Codes
The diagnostic trouble code number is indicated by a suspect parameter number (SPN) and a failure mode indicator (FMI)
number. In the example 000744.04, 000744 is the SPN and 04 is the FMI number.
Diagnostic trouble codes can be displayed using the engagement and monitor unit (EMU) or by using the Service ADVISOR ™
diagnostic application. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-16.)
For in-depth diagnostics on machine specific ECU diagnostic trouble codes, see specific code diagnostic procedures in this
group. Additional engine control unit DTC diagnostic procedures for John Deere PowerTech E ™ engines are located in the
component technical manual (CTM), PowerTech™ E 2.4L and 3.0L Diesel Engines Component Technical Manual . (CTM101019.)
000029.03- Foot Throttle Sensor Out of Range High

220
Input from engine speed control pedal (B19) is shorted to power (5 volts or greater).
Foot Throttle Sensor Out of Range High Diagnostic Procedure

( 1 ) Short to Power Check
Action:
Key switch OFF.

Disconnect engine control unit (ECU) J2 connector (X16). See Main Harness (W3) Component Location . (Group 9015-10.)
Disconnect engine speed control pedal (B19) connector.
Turn key switch ON.
Using a multimeter, check for voltage on wire E34 WHT between pin F3 of ECU J2 connector (X16) and machine ground.
Is voltage indicated?
Result:
YES:Short to power in wire harness. Repair or replace harness. See Main Harness (W3) Wiring Diagram . (Group 9015-10.)
NO:Go to Connector Check.
( 2 ) Connector Check
Action:
Turn key switch OFF.

Check ECU J2 connector (X16) and engine speed control pedal (B19) connector for any damage, corrosion, or debris that could
cause short to power condition for E34 WHT wire.
Are connectors in good condition and free of corrosion and debris?
Result:
YES:Go to Wire Check.

NO:Repair or replace connector. See Main Harness (W3) Wiring Diagram . (Group 9015-10.)
( 3 ) Wire Check
Action:
Key switch OFF.

ECU J2 connector (X16) disconnected.
Engine speed control pedal (B19) disconnected.
Using a multimeter, check for continuity between pin F3 (wire E34 WHT) of ECU J2 connector (X16) and other pins in same
connector.
Is continuity indicated between any circuits?
Result:
YES:Short circuit in wire harness. Repair or replace harness. See Main Harness (W3) Wiring Diagram . (Group 9015-10.)
NO:Engine speed control pedal (B19) malfunction. Replace pedal sensor.
000029.04- Foot Throttle Sensor Out of Range Low
220
Input from engine speed control pedal (B19) is open or shorted to ground.
Foot Throttle Sensor Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check engine control unit (ECU) J2 connector (X16) and engine speed control pedal (B19) connector for corrosion, loose fit,
bent/pushed out terminals or crimp malfunctions. See Main Harness (W3) Component Location . (Group 9015-10.)
Are connectors in good condition?
Result:
YES:Go to Wire Harness Check.

NO:Repair or replace connector(s) or terminal(s) as needed.
( 2 ) Wire Harness Check
Action:
Key switch OFF.

Disconnect ECU J2 connector (X16).
Disconnect engine speed control pedal (B19).
Using a multimeter, check continuity of wire E34 WHT between pin F3 of ECU J2 connector (X16) and engine speed control
pedal (B19) connector.
Is continuity indicated?
Result:
YES:Go to next step in this check.

NO:Open circuit in wire harness. Repair or replace harness. See Main Harness (W3) Wiring Diagram . (Group 9015-10.)
Action:
Check for continuity to ground at pin F3 (wire E34 WHT) of ECU J2 connector (X16).
Is continuity to ground indicated?
Result:
YES:Short to ground in wire harness. Repair or replace harness. See Main Harness (W3) Wiring Diagram . (Group 9015-10.)
NO:Engine speed control pedal (B19) malfunction. Replace pedal sensor.
000029.14- Foot Throttle Sensor (Out of Range High)
220
Engine speed control pedal (B19) is or has been out of range high. Sensor will not reset code until returned to slow idle (zero)
position or the key switch is cycled. Return engine speed control pedal (B19) to slow idle position or cycle key switch.
000091.03- Hand Throttle Sensor Out of Range High

220
Input from engine speed control dial (B18) is shorted to power (5 volts or greater).
Hand Throttle Sensor Out of Range High Diagnostic Procedure

Action:
Key switch OFF.

Disconnect engine speed control dial (B18) connector. See Cab Harness (W2) Component Location . (Group 9015-10.)
Turn key switch ON.
Using a multimeter, check for voltage on wire E33 WHT between pin A4 of ECU J2 connector (X16) and machine ground.
Result:
YES:Short to power in wire harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3)
Wiring Diagram . (Group 9015-10.)
Action:

Check ECU J2 connector (X16), cab harness-to-main harness 47-pin connector (X2), and engine speed control dial (B18)
connector for any damage, corrosion, or debris that could cause short to power condition for E33 WHT wire.
Result:

NO:Repair or replace connector. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3) Wiring Diagram . (Group
9015-10.)
( 3 ) Wire Check
Action:
Key switch OFF.

Engine speed control dial (B18) disconnected.
Using a multimeter, check for continuity between pin A4 (wire E33 WHT) of ECU J2 connector (X16) and other pins in same
connector.
Result:
YES:Short circuit in wire harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3)
NO:Engine speed control dial (B18) malfunction. Replace dial sensor.
000091.04- Hand Throttle Sensor Out of Range Low
220
Input from engine speed control dial (B18) is open or shorted to ground.
Hand Throttle Sensor Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check engine control unit (ECU) J2 connector (X16) and engine speed control dial (B18) connector for corrosion, loose fit,
bent/pushed out terminals or crimp malfunctions. See Main Harness (W3) Component Location . See Cab Harness (W2)
Component Location . (Group 9015-10.)
Result:

Action:
Key switch OFF.

Disconnect engine speed control dial (B18).
Using a multimeter, check continuity of wire E33 WHT between pin A4 of ECU J2 connector (X16) and engine speed control dial
(B18) connector.
Result:

NO:Open circuit in wire harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3)
Action:
Check for continuity to ground at pin A4 (wire E33 WHT) of ECU J2 connector (X16).
Result:
YES:Short to ground in wire harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . See Main Harness
(W3) Wiring Diagram . (Group 9015-10.)
NO:Engine speed control dial (B18) malfunction. Replace dial sensor.
000091.14- Hand Throttle Sensor (Out of Range High)
220
Engine speed control dial (B18) is or has been out of range high. Sensor will not reset code until returned to slow idle (zero)
position or the key switch is cycled. Return engine speed control dial (B18) to slow idle position or cycle key switch.
000100.03- Engine Oil Pressure High
220
Engine oil pressure switch (B6) signal indicates either open circuit or pressure switch malfunction. Oil pressure indicated when
engine is not running (no engine speed). See 000100.31 — Engine Oil Pressure is not Zero with Engine Stopped Diagnostic
Procedure . (CTM101019).
000107.00- Engine Air Filter Switch Data Above Normal

220
Air filter restricted, air filter restriction switch (B1) malfunction, or short circuit in wire harness.
Engine Air Filter Switch Data Above Normal Diagnostic Procedure

( 1 ) Air Filter Restriction Check
Action:
Check air intake system for excessive debris or flow restrictions. See Engine Intake and Exhaust Component Location . (Group
9010-15.)
Is engine air intake system restricted?
Result:
YES:Replace air filters as needed. See Replace Primary Engine Air Filter . See Replace Secondary Engine Air Filter . (Operator’s
Manual.)
NO:Go to Component Check.
( 2 ) Component Check
Action:

Disconnect air filter restriction switch (B1). See Main Harness (W3) Component Location . (Group 9015-10.)
Check for continuity between pins on air filter restriction switch (B1).
Result:
YES:Replace air filter restriction switch (B1).

NO:Go to Short Circuit Check.
( 3 ) Short Circuit Check
Action:
Key switch OFF.

Air filter restriction switch (B1) disconnected.
Disconnect engine control unit (ECU) J2 connector (X16).
Check for continuity between wires F01 YEL and G01 BLK at air filter restriction switch (B1) connector.
Result:
NO:Go to next step in this check.
Action:
Key switch OFF.

Check circuit F01 YEL for ground at pin A on air filter restriction switch (B1) connector.
Is ground present?
Result:
YES:Short to ground in wire F01 YEL. Repair or replace harness. See Main Harness (W3) Wiring Diagram . (Group 9015-10.)
NO:Go to Wire Check.

( 4 ) Wire Check
Action:
Key switch OFF.

Check for continuity between pin E3 (wire F01 YEL) of ECU J2 connector (X16) and other pins in same connector.
Result:
NO:Checks complete.
000171.03- Ambient Air Temperature Out of Range High
220
Open circuit in wire harness to ambient air temperature sensor (B24), either signal or ground; ambient air temperature sensor
(B24) malfunction.
Ambient Air Temperature Out of Range High Diagnostic Procedure

Action:
Key switch OFF.

Check engine control unit (ECU) J2 connector (X16) and ambient air temperature sensor (B24) connector for corrosion, loose fit,
Result:

Action:
Key switch OFF.

Disconnect ambient air temperature sensor (B24).
Using a multimeter, check continuity of wire X04 YEL between pin B4 of ECU J2 connector (X16) and ambient air temperature
sensor (B24) connector.
Check continuity of wire R05 BLK between pin C3 of ECU J2 connector (X16) and ambient air temperature sensor (B24)
connector.
Result:

Action:
Check resistance through ambient air temperature sensor (B24). See Electrical Component Specifications . (Group 9015-20.)
Is sensor resistance within specifications?
Result:
YES:Checks complete.
NO:Replace ambient air temperature sensor (B24).
000171.04- Ambient Air Temperature Out of Range Low
220
Short to ground in signal circuit from ambient air temperature sensor (B24) or sensor malfunction.
Ambient Air Temperature Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check engine control unit (ECU) J2 connector (X16) and ambient air temperature sensor (B24) connector for corrosion, loose fit,
Result:

Action:
Key switch OFF.

Disconnect ambient air temperature sensor (B24).
Using a multimeter, check for continuity to ground at pin B4 (wire X04 YEL) of ECU J2 connector (X16).
Result:
Action:

Check resistance through ambient air temperature sensor (B24). See Electrical Component Specifications . (Group 9015-20.)
Result:
NO:Replace ambient air temperature sensor (B24).
000237.13- Vehicle Identification Number
220
The software versions (major software revision number) between the engine control unit (ECU) and other machine controllers
do not match.
Code is usually a result of a new or different controller being installed on a machine.
Program machine controllers with latest software for the machine in which the they are installed.
000647.05- Fan Coil Output Driver Out of Range Low

220
Open circuit in the wire harness to hydraulic fan speed solenoid (Y30).
Fan Coil Output Driver Out of Range Low Diagnostic Procedure

→NOTE:
Machines without optional reversing fan use fan speed solenoid harness (W9) to connect from main
harness (W3) to hydraulic fan speed solenoid (Y30).
Action:
Key switch OFF.

Check engine control unit (ECU) J2 connector (X16), hydraulic fan speed solenoid (Y30) connector, and main harness-to-fan
speed solenoid harness 2-pin connector (X39) (if not equipped with reversing fan) for corrosion, loose fit, bent/pushed out
terminals or crimp malfunctions. See Main Harness (W3) Component Location . See Fan Speed Solenoid Harness (W9)
Result:

Action:
Key switch OFF.

Disconnect hydraulic fan speed solenoid (Y30).
Using a multimeter, check continuity of wire E42 WHT between pin J4 of ECU J2 connector (X16) and hydraulic fan speed
solenoid (Y30) connector.
Check continuity of wire R50 BLK between pins C1 and D2 of ECU J2 connector (X16) and hydraulic fan speed solenoid (Y30)
connector.
Result:
YES:Go to Component Check.

NO:Open circuit in wire harness. Repair or replace harness. See Main Harness (W3) Wiring Diagram . See Fan Speed Solenoid
Harness (W9) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

Check resistance through hydraulic fan speed solenoid (Y30). See Electrical Component Specifications . (Group 9015-20.)
Is solenoid resistance within specifications?
Result:
NO:Replace hydraulic fan speed solenoid (Y30).
000647.06- Fan Coil Output Driver Out of Range High

220
Open circuit or short to ground in the wire harness to hydraulic fan speed solenoid (Y30).
Fan Coil Output Driver Out of Range High Diagnostic Procedure

→NOTE:
Machines without optional reversing fan use fan speed solenoid harness (W9) to connect from main
harness (W3) to hydraulic fan speed solenoid (Y30).
Action:
Key switch OFF.

Check engine control unit (ECU) J2 connector (X16), hydraulic fan speed solenoid (Y30) connector, and main harness-to-fan
speed solenoid harness 2-pin connector (X39) (if not equipped with reversing fan) for corrosion, loose fit, bent/pushed out
terminals or crimp malfunctions. See Main Harness (W3) Component Location . See Fan Speed Solenoid Harness (W9)
Result:

Action:
Key switch OFF.

Using a multimeter, check continuity of wire E42 WHT between pin J4 of ECU J2 connector (X16) and hydraulic fan speed
Check continuity of wire R50 BLK between pins C1 and D2 of ECU J2 connector (X16) and hydraulic fan speed solenoid (Y30)
connector.
Result:

NO:Open circuit in wire harness. Repair or replace harness. See Main Harness (W3) Wiring Diagram . See Fan Speed Solenoid
Action:
Key switch OFF.

Hydraulic fan speed solenoid (Y30) disconnected.
Check for continuity to ground at pin J4 (wire E42 WHT) of ECU J2 connector (X16).
Result:
YES:Short to ground in wire harness. Repair or replace harness. See Main Harness (W3) Wiring Diagram . See Fan Speed
Solenoid Harness (W9) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

Check for continuity between pin J4 (wire E42 WHT) and pins C1 and D2 (wire R50 BLK) of ECU J2 connector (X16).
Result:
YES:Short circuit in wire harness. Repair or replace harness. See Main Harness (W3) Wiring Diagram . See Fan Speed Solenoid
Action:
Key switch OFF.

Check resistance through hydraulic fan speed solenoid (Y30). See Electrical Component Specifications . (Group 9015-20.)
Result:
NO:Replace hydraulic fan speed solenoid (Y30).
000647.16- Reversing Fan Switch Active Too Long

220
Reversing fan switch (S35) stuck on.
Manual Purge Mode Switch Active Too Long Diagnostic Procedure

( 1 ) Function Check
Action:
Is operator holding reversing fan switch (S35) in MANUAL position too long?
Is reversing fan switch (S35) stuck ON?
Result:
YES:Press or hold reversing fan switch (S35) in MANUAL position for less than 60 seconds. Clean reversing fan switch (S35).
See Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)
NO:Go to next check.
Action:
Disconnect reversing fan switch (S35). See Cab Harness (W2) Component Location . (Group 9015-10.)
Place reversing fan switch (S35) in OFF position.
Check reversing fan switch (S35) for continuity between pins 2 and 3 and between pins 5 and 6.
Result:
YES:Replace reversing fan switch (S35).

Action:
Key switch OFF.

Check engagement and monitor unit (EMU) J2 connector (X42) and reversing fan switch (S35) connector for corrosion, loose fit,
bent/pushed out terminals, or crimp malfunctions. See Cab Harness (W2) Component Location . (Group 9015-10.)
Result:
YES:Go to next check.

NO:Repair or replace connectors or terminals as needed.
Action:
Reversing fan switch (S35) disconnected. See Cab Harness (W2) Component Location . (Group 9015-10.)
Key switch in ON position.
Check for voltage at pin 6 of reversing fan switch (S35) connector.
Is voltage present?
Result:
YES:Circuit is shorted to power. Short can be at the harness or EMU. Repair or replace harness or program EMU.
NO:Checks complete.
000647.30- Fan Coil Output Driver Unknown Fault

220
Signal from reversing fan switch (S35) requesting manual activation of reversing for more than 60 seconds. Switch input goes
to engagement and monitor unit (EMU), which sends switch status to engine control unit (ECU). If ECU receives request to
manually reverse fan for more than 60 seconds, ECU generates diagnostic trouble code (DTC) and disables the reversing fan
function.
Fan Coil Output Driver Unknown Fault Diagnostic Procedure

( 1 ) Operation Check
Action:
Is operator pressing and holding reversing fan switch (S35) in MANUAL position for more than 60 seconds?
Result:
YES:Press and hold reversing fan switch (S35) in MANUAL position for less than 60 seconds.
NO:Go to Switch Check.
( 2 ) Switch Check
Action:
Key switch OFF.

Disconnect reversing fan switch (S35). See Cab Harness (W2) Component Location . (Group 9015-10.)
Push reversing fan switch (S35) to MANUAL position and check continuity through switch. In MANUAL position, switch should
have continuity between pins 2 and 3 and between pins 5 and 6.
Does switch continuity check OK? (Continuity with little resistance when switch is pressed.)
Result:

NO:Replace reversing fan switch (S35).
Action:
Key switch OFF.

Reversing fan switch (S35) disconnected.
Turn key switch ON.
Using a multimeter, check for voltage at pin 6 (wire E41 WHT) of reversing fan switch (S35) connector.
Is system voltage (approximately 12 volts) indicated?
Result:
YES:Short to power in wire harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
NO:Checks complete.
000676.05- Glow Plug Relay Output Out of Range Low

220
Open circuit in the wire harness to glow plug relay (K2).
Glow Plug Relay Output Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check engine control unit (ECU) J1 connector (X15) and glow plug relay connector (X66) for corrosion, loose fit, bent/pushed
out terminals or crimp malfunctions. See Main Harness (W3) Component Location . (Group 9015-10.)
Result:

Action:
Key switch OFF.

Remove glow plug relay (K2).
Using a multimeter, check continuity of wire E03 WHT between pin H4 of ECU J1 connector (X15) and pin 86 of glow plug relay
connector (X66).
Result:

NO:Open circuit in wire E03 WHT. Repair or replace harness. See Main Harness (W3) Wiring Diagram . (Group 9015-10.)
Action:
Check continuity of wire G01 BLK between pin 85 of glow plug relay connector (X66) and ground.
Result:

NO:Open circuit in wire G01 BLK. Repair or replace harness. See Main Harness (W3) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

Check resistance across pins 85 and 86 of glow plug relay (K2). See Electrical Component Specifications . (Group 9015-20.)
Result:
NO:Replace glow plug relay (K2).
000676.06- Glow Plug Relay Output Out of Range High

220
Open circuit or short to ground in the wire harness to glow plug relay (K2).
Glow Plug Relay Output Out of Range High Diagnostic Procedure

Action:
Key switch OFF.

Check engine control unit (ECU) J1 connector (X15) and glow plug relay connector (X66) for corrosion, loose fit, bent/pushed
out terminals or crimp malfunctions. See Main Harness (W3) Component Location . (Group 9015-10.)
Result:
YES:Go to Open Circuit Check.

( 2 ) Open Circuit Check
Action:
Key switch OFF.

Remove glow plug relay (K2).
Using a multimeter, check continuity of wire E03 WHT between pin H4 of ECU J1 connector (X15) and pin 86 of glow plug relay
connector (X66).
Result:

NO:Open circuit in wire E03 WHT. Repair or replace harness. See Main Harness (W3) Wiring Diagram . (Group 9015-10.)
Action:
Check continuity of wire G01 BLK between pin 85 of glow plug relay connector (X66) and ground.
Result:
YES:Go to Short to Ground Check.

NO:Open circuit in wire G01 BLK. Repair or replace harness. See Main Harness (W3) Wiring Diagram . (Group 9015-10.)
( 3 ) Short to Ground Check
Action:
Key switch OFF.

Glow plug relay (K2) removed.
Check for continuity to ground at pin H4 (wire E03 WHT) of ECU J1 connector (X15).
Result:

Action:
Key switch OFF.

Check resistance across pins 85 and 86 of glow plug relay (K2). See Electrical Component Specifications . (Group 9015-20.)
Result:
NO:Replace glow plug relay (K2).
001110.31- Engine Protection Has Shut Down Engine
220
One of the shutdown conditions exists on the engine. Correct engine condition that caused shutdown.
001321.05- Starter Relay Output Out of Range Low

220
Open circuit in wire harness to starter relay (K1).
Starter Relay Output Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check engine control unit (ECU) J2 connector (X16) and starter relay connector (X65) for corrosion, loose fit, bent/pushed out
terminals or crimp malfunctions. See Main Harness (W3) Component Location . (Group 9015-10.)
Result:

Action:
Key switch OFF.

Check resistance across pins 85 and 86 of starter relay (K1). See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:Replace starter relay (K1).
Action:
Key switch OFF.

Remove starter relay (K1).
Using a multimeter, check continuity of wire R04 BLK between pin C2 of ECU J2 connector (X16) and pin 85 of starter relay
connector (X65).
Result:

NO:Open circuit in wire R04 BLK. Repair or replace harness. See Main Harness (W3) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

Remove polarity sensing diode (V2).
Check continuity of wire J07 TAN between pin 4 of diode block connector (X64) and pin 86 of starter relay connector (X65).
Result:
001321.06- Starter Relay Output Out of Range High

220
Open circuit or short to ground in the wire harness to starter relay (K1).
Starter Relay Output Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check engine control unit (ECU) J2 connector (X16) and starter relay connector (X65) for corrosion, loose fit, bent/pushed out
terminals or crimp malfunctions. See Main Harness (W3) Component Location . (Group 9015-10.)
Result:

Action:
Key switch OFF.

Check resistance across pins 85 and 86 of starter relay (K1). See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:Replace starter relay (K1).
Action:
Key switch OFF.

Using a multimeter, check continuity of wire R04 BLK between pin C2 of ECU J2 connector (X16) and pin 85 of starter relay
connector (X65).
Result:

Action:
Key switch OFF.

Remove polarity sensing diode (V2).
Check continuity of wire J07 TAN between pin 4 of diode block connector (X64) and pin 86 of starter relay connector (X65).
Result:
YES:Go to Short Circuit Check.

Action:
Key switch OFF.

Using a multimeter, check for continuity to ground at pin C2 (wire R04 BLK) of ECU J2 connector (X16).
Result:
NO:Checks complete.
001321.16- Starter Relay Output Moderately High Value
220
Starter motor engaged for 120 seconds. Starter motor needs to be inactive for 120 seconds to reset code.
001508.00- Hydraulic Oil Temperature Data Above Normal
220
Hydraulic oil temperature is above 104.4°C (220°F) or hydraulic oil temperature sensor (B2) malfunction.
Hydraulic Oil Temperature Data Above Normal Diagnostic Procedure

( 1 ) Temperature Check
Action:
Verify temperature of hydraulic oil in hydraulic oil tank is more than 104.4°C (220°F).
Is hydraulic oil temperature overheated?
Result:
YES:Allow machine to cool before operating. If overheating persists, diagnose cause for oil overheating. See Hydraulic Oil
Overheats . (Group 9025-15.)
Action:

Disconnect hydraulic oil temperature sensor (B2). See Main Harness (W3) Component Location . (Group 9015-10.)
Measure resistance across pins A and B of hydraulic oil temperature sensor (B2). Compare resistance to specification. See
Electrical Component Specifications . (Group 9015-20.)
Is resistance within specification?
Result:
NO:Replace hydraulic oil temperature sensor (B2).
001508.03- Hydraulic Oil Temperature Out of Range High
220
Open circuit in wire harness to hydraulic oil temperature sensor (B2), either signal or ground; hydraulic oil temperature sensor
(B2) malfunction.
Hydraulic Oil Temperature Out of Range High Diagnostic Procedure

Action:
Key switch OFF.

Check engine control unit (ECU) J2 connector (X16) and hydraulic oil temperature sensor (B2) connector for corrosion, loose fit,
Result:

Action:
Key switch OFF.

Disconnect hydraulic oil temperature sensor (B2).
Using a multimeter, check continuity of wire X02 YEL between pin G4 of ECU J2 connector (X16) and hydraulic oil temperature
sensor (B2) connector.
Check continuity of wire R05 BLK between pin C3 of ECU J2 connector (X16) and hydraulic oil temperature sensor (B2)
connector.
Result:

Action:

Check resistance through hydraulic oil temperature sensor (B2). See Electrical Component Specifications . (Group 9015-20.)
Result:
001508.04- Hydraulic Oil Temperature Out of Range Low
220
Short to ground in signal circuit from hydraulic oil temperature sensor (B2) or sensor malfunction.
Hydraulic Oil Temperature Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check engine control unit (ECU) J2 connector (X16) and hydraulic oil temperature sensor (B2) connector for corrosion, loose fit,
Result:

Action:
Key switch OFF.

Disconnect hydraulic oil temperature sensor (B2).
Using a multimeter, check for continuity to ground at pin G4 (wire X02 YEL) of ECU J2 connector (X16).
Result:
Action:

Check resistance through hydraulic oil temperature sensor (B2). See Electrical Component Specifications . (Group 9015-20.)
Result:
001713.00- Hydraulic Filter Restriction Switch Data Above Normal

220
Hydraulic oil filter restriction switch (B3) closed or switch malfunction. Input voltage is less than 1 volt for 60 seconds with
engine running for more than 10 seconds and hydraulic oil temperature more than 38°C (100°F).
Hydraulic Filter Restriction Switch Data Above Normal Diagnostic

Procedure
( 1 ) Filter Check
Action:
Replace hydraulic oil filter. See Replace Hydraulic Oil Filter . (Operator′s Manual.)
Using Service ADVISOR ™ or engagement and monitor unit (EMU), clear diagnostic trouble codes (DTCs).
Operate machine and check active DTCs. Does engine control unit (ECU) DTC 1713.00 return?
Result:

NO:Checks complete.
Action:

Disconnect hydraulic oil filter restriction switch (B3). See Main Harness (W3) Component Location . (Group 9015-10.)
Check for continuity between pin on switch and machine ground.
Result:
YES:Replace hydraulic oil filter restriction switch (B3).

NO:Go to Wire Harness Check.
Action:
Key switch OFF.

Hydraulic oil filter restriction switch (B3) disconnected.
Check for continuity between wires F02 YEL and G01 BLK at hydraulic oil filter restriction switch (B3) connector.
Result:
Action:
Key switch off.

Hydraulic oil filter restriction switch (B3) disconnected.
Check for ground at pin J1 (wire F02 YEL) of ECU J2 connector (X16).
Result:
YES:Short to ground in wire F02 YEL. Repair or replace harness. See Main Harness (W3) Wiring Diagram . (Group 9015-10.)
NO:Checks complete.
002023.09- No EMU on CAN Bus Abnormal Data Rate
220
Controller area network (CAN) timeout or invalid data. The engine control unit does not detect engagement and monitor unit
(EMU) on CAN.
No EMU Data on CAN Bus Abnormal Data Range Diagnostic Procedure

Action:
Key switch OFF.

Check EMU connector (X41), cab harness-to-main harness connector (X2), and ECU J2 connector (X16) for corrosion, loose fit,
bent/pushed out terminals or crimp malfunctions that could cause controller area network (CAN) communication problems. See
Cab Harness (W2) Component Location . See Main Harness (W3) Component Location . (Group 9015-10.)
Result:
YES:Go to CAN Circuit Check

( 2 ) CAN Circuit Check
Action:
Check CAN circuit between ECU and EMU. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.)
Does CAN circuit test good?
Result:
NO:Repair CAN circuit.
522826.05- Fan Reversing Coil Output Out of Range Low

220
Open circuit in the wire harness to either hydraulic reversing fan solenoid A (Y31) or hydraulic reversing fan solenoid B (Y32).
Fan Reversing Coil Output Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check engine control unit (ECU) J2 connector (X16), hydraulic reversing fan solenoid A (Y31) connector, and hydraulic reversing
fan solenoid B (Y32) connector for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See Main Harness (W3)
Result:

Action:
Key switch OFF.

Disconnect hydraulic reversing fan solenoid A (Y31).
Using a multimeter, check continuity of wire E43 WHT between pin M3 of ECU J2 connector (X16) and hydraulic reversing fan
solenoid A (Y31) connector.
Check continuity of wire G01 BLK between hydraulic reversing fan solenoid A (Y31) connector and machine ground.
Result:

Action:
Key switch OFF.

Disconnect hydraulic reversing fan solenoid B (Y32).
Using a multimeter, check continuity of wire E44 WHT between pin K4 of ECU J2 connector (X16) and hydraulic reversing fan
solenoid B (Y32) connector.
Check continuity of wire G01 BLK between hydraulic reversing fan solenoid B (Y32) connector and machine ground.
Result:

Action:
Key switch OFF.

Check resistance through hydraulic reversing fan solenoid A (Y31) and hydraulic reversing fan solenoid B (Y32). See Electrical
Component Specifications . (Group 9015-20.)

Result:
NO:Replace solenoid(s).
522826.06- Fan Reversing Coil Output Out of Range High

220
Short to ground in the wire harness to either hydraulic reversing fan solenoid A (Y31) or hydraulic reversing fan solenoid B
(Y32).
Fan Reversing Coil Output Out of Range High Diagnostic Procedure

Action:
Key switch OFF.

Check engine control unit (ECU) J2 connector (X16), hydraulic reversing fan solenoid A (Y31) connector, and hydraulic reversing
fan solenoid B (Y32) connector for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See Main Harness (W3)
Result:

Action:
Key switch OFF.

Disconnect hydraulic reversing fan solenoid A (Y31).
Disconnect hydraulic reversing fan solenoid B (Y32).
Check for continuity to ground at pin M3 (wire E43 WHT) of ECU J2 connector (X16).
Check for continuity to ground at pin K4 (wire E44 WHT) of ECU J2 connector (X16).
Result:
Action:
Key switch OFF.

Hydraulic reversing fan solenoid A (Y31) disconnected.
Hydraulic reversing fan solenoid B (Y32) disconnected.
Check for continuity between pin 1 (wire E43 WHT) and pin 2 (G01 BLK) of reversing fan solenoid A (Y31) connector.
Check for continuity between pin 1 (wire E44 WHT) and pin 2 (G01 BLK) of reversing fan solenoid B (Y32) connector.
Result:
YES:Short circuit in wire harness. Repair or replace harness. See Main Harness (W3) Wiring Diagram . See Fan Speed Solenoid
Section 9001 - DIAGNOSTIC TROUBLE CODES (DTCS) Group 20: Engagement and Monitor Unit (EMU) Diagnostic Trouble Codes
Action:
Key switch OFF.

Check resistance through hydraulic reversing fan solenoid A (Y31) and hydraulic reversing fan solenoid B (Y32). See Electrical
Component Specifications . (Group 9015-20.)
Result:
NO:Replace solenoid(s).
Group 20 - Engagement and Monitor Unit (EMU) Diagnostic Trouble

Codes
Engagement and Monitor Unit (EMU) Diagnostic Trouble Codes
The diagnostic trouble code number is indicated by a suspect parameter number (SPN) and a failure mode indicator (FMI)
number. In the example 000744.04, 000744 is the SPN and 04 is the FMI number.
Diagnostic trouble codes can be displayed using the engagement and monitor unit (EMU) or by using the Service ADVISOR ™
diagnostic application. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
→NOTE:
For in-depth diagnostics on all EMU diagnostic trouble codes, see specific code diagnostic procedure in
this group.
Perform visual inspection of components prior to diagnostics and tests. These conditions my affect
diagnostics and test results.
000070.02- Park Brake Release Input Erratic or Bad Data

239
Park brake release and park brake run inputs from park brake switch (S2) to engagement and monitor unit (EMU) are an invalid
combination.
Park Brake Release Input Erratic or Bad Data Diagnostic Procedure

Action:

Check park brake switch (S2) connector and EMU J2 connector (X42) for corrosion, loose fit, bent/pushed out terminals or crimp
malfunctions. See Cab Harness (W2) Component Location . (Group 9015-10.)
Result:
YES:Go to Switch Check.

( 2 ) Switch Check
Action:
Key switch OFF.

Disconnect park brake switch (S2) connector.
Check continuity through park brake switch (S2). See System Functional Schematic . (Group 9015-10.)
Is switch continuity correct?
Result:

NO:Replace park brake switch (S2).
( 3 ) Continuity Check
Action:
Key switch OFF.

Park brake switch (S2) disconnected.
Disconnect EMU J2 connector (X42).
Check continuity of wire T01 BLU between pin F of EMU J2 connector (X42) and park brake switch (S2) connector.
Check continuity of wire T02 BLU between pin K of EMU J2 connector (X42) and park brake switch (S2) connector.
Result:

NO:Open circuit in wiring harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

EMU J2 connector (X42) disconnected.
Check for continuity between pin F (wire T01 BLU) and pin K (wire T02 BLU) of EMU J2 connector (X42).
Result:
YES:Short circuit in wiring harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
NO:Go to Short to Ground Check.
Action:
Key switch OFF.

Check for continuity to ground at pin F (wire T01 BLU) of EMU J2 connector (X42).
Check for continuity to ground at pin K (wire T02 BLU) of EMU J2 connector (X42).
Result:
YES:Short to ground in wiring harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
NO:Go to Short to Power Check.
Action:
Key switch OFF.

Turn key switch ON.
Check for voltage on T01 BLU wire at park brake switch connector.
Result:
YES:Short to power in wiring harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
NO:Checks complete.
000070.04- Park Brake Release Input Out of Range Low

239
Park brake release input out of range/low. Park brake release input has short to ground or open circuit.
Park Brake Release Input Out of Range Low Diagnostic Procedure

Action:

Result:

( 2 ) Switch Check
Action:
Key switch OFF.

Result:

Action:
Key switch OFF.

Result:
YES:Open circuit in wiring harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

Result:
NO:Checks complete.
000096.03- Fuel Level Sensor Out of Range High

239
Fuel level sensor (B4) circuit open or shorted to power. Sensor input is greater than 4.8 volts for more than 30 seconds.
Fuel Level Sensor Out of Range High Diagnostic Procedure

Action:

Check fuel level sensor (B4) connector, cab harness-to-main harness connector (X2), engagement and monitor unit (EMU) J1
connector (X41), and EMU J2 connector (X42) for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See Cab
Harness (W2) Component Location . See Main Harness (W3) Component Location . (Group 9015-10.)
Result:

Action:
Key switch OFF.

Disconnect fuel level sensor (B4).
Using a multimeter, check continuity of Y01 YEL wire between pin L of EMU J1 connector (X41) and fuel level sensor (B4)
connector.
Check continuity of R01 BLK wire between pin A of EMU J2 connector (X42) and fuel level sensor (B4) connector.
Result:
YES:Go to Short to Power Check.

Action:
Key switch OFF.

Fuel level sensor (B4) disconnected.
Connect EMU J2 connector (X42).
Turn key switch ON.
Check for voltage on Y01 YEL wire at fuel level sensor (B4) connector.
Check for voltage on R01 BLK wire at fuel level sensor (B4) connector.
Result:
NO:Go to Sensor Check.
( 4 ) Sensor Check
Action:
Check resistance of fuel level sensor. See Electrical Component Specifications . (Group 9015-20.)
Is fuel level sensor resistance within specification?
Result:
NO:Replace fuel level sensor (B4).
000096.04- Fuel Level Sensor Out of Range Low

239
Fuel level sensor (B4) input shorted to ground. Sensor input is less than 0.2 volts for more than 30 seconds.
Fuel Level Sensor Out of Range Low Diagnostic Procedure

Action:

Check fuel level sensor (B4) connector, cab harness-to-main harness connector (X2), engagement and monitor unit (EMU) J1
connector (X41), and EMU J2 connector (X42) for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See Cab
Harness (W2) Component Location . See Main Harness (W3) Component Location . (Group 9015-10.)
Result:

Action:
Key switch OFF.

Disconnect fuel level sensor (B4).
Using a multimeter, check for continuity between wire Y01 YEL and wire R01 BLK at fuel level sensor (B4) connector.
Result:
Action:
Key switch OFF.

Fuel level sensor (B4) disconnected.
Using a multimeter, check for continuity to ground at pin L (wire Y01 YEL) of EMU J1 connector (X41).
Result:
YES:Go to Sensor Check.

NO:Short to ground in wire harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3)
( 3 ) Sensor Check
Action:
Check resistance of fuel level sensor. See Electrical Component Specifications . (Group 9015-20.)
Is fuel level sensor resistance within specification?
Result:
NO:Replace fuel level sensor (B4).
000158.00- System Voltage Data Above Normal
239
Engagement and monitor unit (EMU) measures abnormally high system voltage. Voltage input to EMU is greater than 16.2 volts
for 5 seconds.
System Voltage Data Above Normal Diagnostic Procedure

( 1 ) Voltage Check
Action:
Start engine.
Check voltage across positive and negative battery terminals.
Is voltage 16.2 volts or more?
Result:
YES:Go to Alternator Check.

NO:Engagement and monitor unit (EMU) malfunction. Program EMU.
( 2 ) Alternator Check
Action:
Check alternator. Perform Alternator Test. (Group 9015-20.)

Does alternator test good?
Result:
YES:Engagement and monitor unit (EMU) malfunction. Program EMU.

NO:Replace alternator.
000158.01- System Voltage Data Below Normal

239
Engagement and monitor unit (EMU) measures abnormally low system voltage. Voltage input to EMU is less than 11.7 volts for
5 seconds.
→NOTE:
If other codes are present for low battery voltage on other controllers, perform alternator test procedure.
See Alternator Test . (Group 9015-20.)
System Voltage Data Below Normal Diagnostic Procedure

( 1 ) Fuse Check
Action:

Remove monitor unswitched power 10 A fuse (F2). See Fuse and Relay Specifications . (Group 9015-10.)
Check fuse (F2) for continuity.
Is continuity indicated for fuse?
Result:
YES:Go to Battery Voltage Check.

NO:Replace fuse.
( 2 ) Battery Voltage Check
Action:
Key switch OFF.

Check voltage across positive and negative battery terminals.
Is voltage less than 11.7 volts?
Result:
YES:Check alternator output voltage. See Alternator Test . (Group 9015-20.) Charge or replace battery. See Using Battery
Charger . (Operator’s Manual.)
Action:
Key switch OFF.

Check fuse block 2 connector (X62), cab harness-to-main harness connector (X1), and EMU J2 connector (X42) for corrosion,
loose fit, bent/pushed out terminals or crimp malfunctions. See Cab Harness (W2) Component Location . See Main Harness
(W3) Component Location . (Group 9015-10.)
Result:

Action:
Key switch OFF.

Remove fuse (F2).

Using a multimeter, check wire P05 RED for continuity between fuse (F2) and pin H of EMU J2 connector (X42).
Result:

Action:
Key switch OFF.

Check for continuity to ground at pin H (wire P05 RED) of EMU J2 connector (X42).
Result:
NO:Checks complete.
000162.04- 2-Speed Switch Input Out of Range Low

239
Two speed switch (S25) input out of range low.
Switch Input Low Diagnostic Procedure—Manual Control Machines

Action:

Check left control lever 8-pin connector (X24), cab harness-to-main harness 47-pin connector (X2), main harness-to-control
lever harness 12-pin connector (X28), and EMU J2 connector (X42) for corrosion, loose fit, bent/pushed out terminals or crimp
malfunctions. See Cab Harness (W2) Component Location . See Main Harness (W3) Component Location . See Control Lever
Harness (W6) Component Location . (Group 9015-10.)
Result:

Action:

Disconnect left control lever 8-pin connector (X24).
Using a multimeter, check for continuity to ground at pin M (wire T04 BLU) of EMU J2 connector (X42).
Result:
(W3) Wiring Diagram . See Control Lever Harness (W6) Wiring Diagram . (Group 9015-10.)
( 3 ) Switch Check
Action:
Key switch OFF.

Left control lever 8-pin connector (X24) disconnected.
Press two speed switch (S25) and check continuity through switch between pins 4 and 8 of left control lever 8-pin connector
(X24) (switch side).
Result:

NO:Replace two speed switch (S25).
Action:
Key switch OFF.

Left control lever 8-pin connector (X24) disconnected.
Check for continuity to ground at pin 4 of left control lever 8-pin connector (X24) (switch side).
Result:
YES:Short to ground in switch or switch harness. Replace switch.

NO:Checks complete.
Switch Input Low Diagnostic Procedure—EH Control Machines

Action:

Check left joystick 8-pin connector (X24) and EMU J2 connector (X42) for corrosion, loose fit, bent/pushed out terminals or
crimp malfunctions. See Cab Harness (W2) Component Location . (Group 9015-10.)
Result:

Action:

Disconnect left joystick 8-pin connector (X24).
Using a multimeter, check for continuity to ground at pin M (wire T04 BLU) of EMU J2 connector (X42).
Result:
YES:Short to ground in wire harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
( 3 ) Switch Check
Action:
Key switch OFF.

Left joystick 8-pin connector (X24) disconnected.
Press two speed switch (S25) and check continuity through switch between pins 4 and 8 of left joystick 8-pin connector (X24)
(switch side).
Result:

NO:Replace two speed switch (S25).
Action:
Key switch OFF.

Check for continuity to ground at pin 4 of left joystick 8-pin connector (X24) (switch side).
Result:

NO:Checks complete.
000920.05- Alarm Output Out of Range Low

239
Low current output from engagement and monitor unit (EMU) to EMU warning alarm (H4); short to power or open circuit.
Alarm Output Out of Range Low Diagnostic Procedure

Action:

Check EMU J1 connector (X41) and EMU warning alarm (H4) connector for corrosion, loose fit, bent/pushed out terminals or
Result:

Action:

Disconnect EMU warning alarm (H4).
Using a multimeter, check continuity of wire Z01 GRY between pin F of EMU J1 connector (X41) and EMU warning alarm (H4)
connector.
Result:

NO:Open circuit in wire Z01 GRY. Repair or replace wire. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
Action:
Check wire G02 BLK for continuity to ground at EMU warning alarm (H4) connector.
Result:

NO:Open circuit in wire G02 BLK. Repair or replace wire. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

EMU warning alarm (H4) disconnected.
Turn key switch ON.
Check for voltage on wire Z01 GRY at pin F of EMU J1 connector (X41).
Result:
Action:

Check EMU J1 connector (X41) and EMU warning alarm (H4) connector for any damage, corrosion, or debris that could cause
short to power condition for Z01 GRY wire.
Result:

NO:Repair or replace connector. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
Action:
Check for continuity between pin F (wire Z01 GRY) of EMU J1 connector (X41) and other pins in same connector.
Result:
YES:Short circuit in wire harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
NO:Replace EMU warning alarm (H4).
000920.06- Alarm Output Out of Range High

239
Short to ground or shorted load in EMU warning alarm (H4) circuit, causing high output current from engagement and monitor
unit (EMU).
Alarm Output Out of Range High Diagnostic Procedure

Action:

Check EMU J1 connector (X41) and EMU warning alarm (H4) connector for corrosion, loose fit, bent/pushed out terminals or
Result:
YES:Go to Short to Ground Check.

Action:

Disconnect EMU warning alarm (H4).
Using a multimeter, check for continuity to ground at pin F (wire Z01 GRY) of EMU J1 connector (X41).
Result:
YES:Short to ground in wire Z01 GRY. Repair or replace wire. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
Action:
Check wire G02 BLK for continuity to ground at EMU warning alarm (H4) connector.
Result:

NO:Open circuit in wire G02 BLK. Repair or replace wire. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

Check EMU J1 connector (X41) and EMU warning alarm (H4) connector for any damage, corrosion, or debris that could cause
short circuit for Z01 GRY wire.
Result:

Action:
Check for continuity between pin F (wire Z01 GRY) of EMU J1 connector (X41) and other pins in same connector.
Result:
NO:Replace EMU warning alarm (H4).
001196.11- Anti Theft Unknown Fault
239
The engagement and monitor unit (EMU) has not received expected anti-theft system status from the engine control unit
(ECU).
Anti Theft Unknown Fault Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J1 connector (X41), cab harness-to-main harness connector (X2), and ECU connector (X16) for corrosion, loose fit,
Result:

Action:
Check CAN circuit between EMU and ECU. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.)
Result:
001504.04- Seat Switch Input Out of Range Low

239
Input from seat switch (S4) shorted to ground.
Seat Switch Input Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J2 connector (X42) and seat switch (S4) connector for corrosion, loose fit, bent/pushed out terminals or crimp
Result:
YES:Go to Wire Harness Check

Action:
Key switch OFF.

Disconnect seat switch (S4).
Using a multimeter, check for continuity to ground at pin P (wire M01 PUR) of EMU J2 connector (X42).
Result:
( 3 ) Switch Check
Action:
Key switch OFF.

Seat switch (S4) disconnected.
Press seat switch (S4) and check continuity through switch between pins 1 and 2 of seat switch (S4) connector (switch side).
Result:

NO:Replace seat switch (S4).
Action:
Key switch OFF.

Seat switch (S4) disconnected.
Check for continuity to ground at pins 1 and 2 of seat switch (S4) connector (switch side).
Result:
NO:Checks complete.
001550.05- AC Compressor Clutch Output Out of Range Low

239
Air conditioning option is enabled and the return current is low compared to expected value.
AC Compressor Clutch Output Out of Range Low Diagnostic Procedure

Action:

Check EMU J1 connector (X41), cab harness-to-main harness 47-pin connector (X2), and main harness-to-air conditioner and
heater harness 14-pin connector (X8) for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See Cab
Harness (W2) Component Location . See Heater and Air Conditioner Harness (W16) Component Location . (Group 9015-10.)
Result:

NO:Repair or replace connector. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3) Wiring Diagram . See Heater
and Air Conditioner Harness (W16) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

Disconnect EMU J1 connector (X41). See Cab Harness (W2) Component Location . (Group 9015-10.)
Disconnect air conditioner compressor clutch relay (K7).
Using a multimeter, check for continuity of wire A12 ORG between pin R of EMU J1 connector (X41) and pin 86 of air conditioner
compressor clutch relay (K7).
Result:

Wiring Diagram . See Heater and Air Conditioner Harness (W16) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

Air conditioner compressor clutch relay (K7) disconnected.
Check for continuity to ground at pin R (wire A12 ORG) of EMU J1 connector (X41).
Result:
(W3) Wiring Diagram . See Heater and Air Conditioner Harness (W16) Wiring Diagram . (Group 9015-10.)
Action:

Disconnect air conditioner compressor clutch relay (K7), See Heater and Air Conditioner Harness (W16) Component Location .
(Group 9015-10.)
Check resistance through relay coil at pins 85 and 86 of relay. See Electrical Component Specifications . (Group 9015-20.)
Result:
NO:Replace air conditioner compressor clutch relay (K7).
001550.06- AC Compressor Clutch Output Out of Range High

239
AC option is enabled and the return current is high compared to the expected value. Possibly shorted air conditioner
compressor clutch relay (K7) or short to power.
AC Compressor Clutch Output Out of Range High Diagnostic Procedure

Action:

Disconnect air conditioner compressor clutch relay (K7), See Heater and Air Conditioner Harness (W16) Component Location .
(Group 9015-10.)
Check resistance through relay coil at pins 85 and 86 of relay. See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:Replace air conditioner compressor clutch relay (K7).
Action:
Key switch OFF.

Disconnect air conditioner compressor clutch relay (K7).
Turn key switch ON.
Using a multimeter, check for voltage on wire A12 ORG between pin R of EMU J1 connector (X41) and machine ground.
Result:
Wiring Diagram . See Heater and Air Conditioner Harness (W16) Wiring Diagram . (Group 9015-10.)
Action:

Check EMU J1 connector (X41), cab harness-to-main harness 47-pin connector (X2), and main harness-to-air conditioner and
heater harness 14-pin connector (X8) for any damage, corrosion, or debris that could cause short to power condition for A12
ORG wire.
Result:

NO:Repair or replace connector. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3) Wiring Diagram . See Heater
and Air Conditioner Harness (W16) Wiring Diagram . (Group 9015-10.)
( 4 ) Wire Check
Action:
Key switch OFF.

Air conditioner compressor clutch relay (K7) disconnected.
Using a multimeter, check for continuity between pin R (wire A12 ORG) of EMU J1 connector (X41) and other pins in same
connector.
Result:
Wiring Diagram . See Control Lever Harness (W6) Wiring Diagram . (Group 9015-10.)
NO:Checks complete.
002000.09- No ECU Data on CAN Bus Abnormal Data Range
239
The engagement and monitor unit (EMU) is not receiving any controller area network (CAN) data from the engine control unit
(ECU).
No ECU Data on CAN Bus Abnormal Data Range Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J1 connector (X41), cab harness-to-main harness connector (X2), and ECU connector (X16) for corrosion, loose fit,
Result:

Action:
Check CAN circuit between EMU and ECU. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.)
Result:
002228.09- No HCU Data on CAN Bus Abnormal Data Range
239
The engagement and monitor unit (EMU) is not receiving any controller area network (CAN) data from the hydraulic control unit
(HCU).
No HCU Data on CAN Bus Abnormal Data Range Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J1 connector (X41), cab harness-to-main harness connector (X2), and HCU connector (X45) for corrosion, loose fit,
Result:

Action:
Check CAN circuit between EMU and HCU. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.)
Result:
003413.04- Door Switch Input Out of Range Low

239
Input from cab door switch (S13) shorted to ground.
Seat Switch Input Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J2 connector (X42) and cab door switch (S13) connector for corrosion, loose fit, bent/pushed out terminals or crimp
Result:

Action:
Key switch OFF.

Disconnect cab door switch (S13).
Using a multimeter, check for continuity to ground at pin E (wire M03 PUR) of EMU J2 connector (X42).
Result:
( 3 ) Switch Check
Action:
Key switch OFF.

Cab door switch (S13) disconnected.
Actuate cab door switch (S13) and check continuity through switch between pins 1 and 2 of cab door switch (S13) connector
(switch side).
Does switch continuity check OK? (Continuity with little resistance when switch is actuated.)
Result:

NO:Replace cab door switch (S13).
Action:
Key switch OFF.

Cab door switch (S13) disconnected.
Check for continuity to ground at pins 1 and 2 of cab door switch (S13) connector (switch side).
Result:

NO:Checks complete.
003597.03- 5 Volt Sensor Supply 1 Out of Range High

239
The auxiliary proportional switch (B15) 5 volt power source from engagement and monitor unit (EMU) is above specified value.
Possible causes include short to power in circuit or voltage regulator malfunction.
Sensor Supply Voltage High Diagnostic Procedure—Manual Control

Machines
Action:
Key switch OFF.

Disconnect right control lever 12-pin connector (X22). See Control Lever Harness (W6) Component Location . (Group 9015-10.)
Turn key switch ON.
Using a multimeter, check for voltage on wire P20 RED between pin A of EMU J3 connector (X43) and machine ground.
Check for voltage on wire R20 BLK between pin C of EMU J3 connector (X43) and machine ground.
Result:
Action:

Check EMU J3 connector (X43), cab harness-to-main harness 47-pin connector (X2), main harness-to-control lever harness 12-
pin connector (X28), and right control lever 12-pin connector (X22) for any damage, corrosion, or debris that could cause short
to power condition for P20 RED and/or R20 BLK wires.
Result:

NO:Repair or replace connector. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3) Wiring Diagram . See Control
Lever Harness (W6) Wiring Diagram . (Group 9015-10.)
( 3 ) Wire Check
Action:
Key switch OFF.

Right control lever 12-pin connector (X22) disconnected.
Using a multimeter, check for continuity between pin A (wire P20 RED) of EMU J3 connector (X43) and other pins in same
connector.
Check for continuity between pin C (wire R20 BLK) of EMU J3 connector (X43) and other pins in same connector.
Result:
NO:Checks complete.
Sensor Supply Voltage High Diagnostic Procedure—EH Control Machines

Action:
Key switch OFF.

Disconnect right joystick 12-pin connector (X22).
Turn key switch ON.
Using a multimeter, check for voltage on wire P20 RED between pin A of EMU J3 connector (X43) and machine ground.
Check for voltage on wire R20 BLK between pin C of EMU J3 connector (X43) and machine ground.
Result:
Action:

Check EMU J3 connector (X43) and right joystick 12-pin connector (X22) for any damage, corrosion, or debris that could cause
short to power condition for P20 RED and/or R20 BLK wires.
Result:

( 3 ) Wire Check
Action:
Key switch OFF.

Right joystick 12-pin connector (X22) disconnected.
Using a multimeter, check for continuity between pin A (wire P20 RED) of EMU J3 connector (X43) and other pins in same
connector.
Check for continuity between pin C (wire R20 BLK) of EMU J3 connector (X43) and other pins in same connector.
Result:
NO:Checks complete.
003597.04- 5 Volt Sensor Supply 1 Out of Range Low

239
The auxiliary proportional switch (B15) 5 volt power source from engagement and monitor unit (EMU) is below specified value.
Possible causes include short to ground in circuit or voltage regulator malfunction.
Sensor Supply Voltage Low Diagnostic Procedure—Manual Control

Machines
Action:
Key switch OFF.

pin connector (X28), and right control lever 12-pin connector (X22) for corrosion, loose fit, bent/pushed out terminals or crimp
Result:

Action:
Key switch OFF.

Disconnect right control lever 12-pin connector (X22).
Using a multimeter, check for continuity to ground at pin A (wire P20 RED) of EMU J3 connector (X43).
Result:
NO:Checks complete.
Sensor Supply Voltage Low Diagnostic Procedure—EH Control Machines

Action:
Key switch OFF.

Check EMU J3 connector (X43) and right joystick 12-pin connector (X22) for corrosion, loose fit, bent/pushed out terminals or
Result:

Action:
Key switch OFF.

Using a multimeter, check for continuity to ground at pin A (wire P20 RED) of EMU J3 connector (X43).
Result:
NO:Checks complete.
520850.04- Over Ride Switch Input Out of Range Low

239
Input from auxiliary hydraulic override switch (S21) shorted to ground.
Over Ride Switch Input Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J2 connector (X42) and auxiliary hydraulic override switch (S21) connector for corrosion, loose fit, bent/pushed out
terminals or crimp malfunctions. See Cab Harness (W2) Component Location . (Group 9015-10.)
Result:

Action:
Key switch OFF.

Disconnect auxiliary hydraulic override switch (S21).
Using a multimeter, check for continuity to ground at pin B (wire H06 GRN) of EMU J2 connector (X42).
Result:
( 3 ) Switch Check
Action:
Key switch OFF.

Auxiliary hydraulic override switch (S21) disconnected.
Press auxiliary hydraulic override switch (S21) and check continuity through switch. When pressed, switch should have
continuity between pins 2 and 3 of auxiliary hydraulic override switch (S21).
Result:

NO:Replace auxiliary hydraulic override switch (S21).
Action:
Key switch OFF.

Auxiliary hydraulic override switch (S21) disconnected.
Check for continuity to ground at pins 2 and 3 of auxiliary hydraulic override switch (S21).
Result:
YES:Short to ground in switch. Replace switch.

NO:Checks complete.
521050.04- Aux Flow On-Off Switch Input Out of Range Low

239
Input from auxiliary flow set switch (S28) shorted to ground.
Switch Input Low Diagnostic Procedure—Manual Control Machines

Action:

Check right control lever 12-pin connector (X22), cab harness-to-main harness 47-pin connector (X2), main harness-to-control
lever harness 12-pin connector (X28), and EMU J3 connector (X43) for corrosion, loose fit, bent/pushed out terminals or crimp
Result:

Action:

Using a multimeter, check for continuity to ground at pin K (wire H24 GRN) of EMU J3 connector (X43).
Result:
( 3 ) Switch Check
Action:
Key switch OFF.

Press auxiliary flow set switch (S28) and check continuity through switch between pins 4 and 8 of right control lever 12-pin
connector (X22) (switch side).
Result:

NO:Replace auxiliary flow set switch (S28).
Action:
Key switch OFF.

Check for continuity to ground at pin 4 of right control lever 12-pin connector (X22) (switch side).
Result:

NO:Checks complete.
Switch Input Low Diagnostic Procedure—EH Control Machines

Action:

Check left joystick 8-pin connector (X24) and EMU J3 connector (X43) for corrosion, loose fit, bent/pushed out terminals or
Result:

Action:

Disconnect left joystick 8-pin connector (X24).
Using a multimeter, check for continuity to ground at pin K (wire H24 GRN) of EMU J3 connector (X43).
Result:
( 3 ) Switch Check
Action:
Key switch OFF.

Press auxiliary flow set switch (S28) and check continuity through switch between pins 3 and 8 of left joystick 8-pin connector
(X24) (switch side).
Result:

NO:Replace auxiliary flow set switch (S28).
Action:
Key switch OFF.

Check for continuity to ground at pin 3 of left joystick 8-pin connector (X24) (switch side).
Result:

NO:Checks complete.
522379.05- Park Brake Release Output Out of Range Low

239
Open circuit or short to power (with driver off) in circuit to park brake solenoid (Y5).
Park Brake Release Output Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J1 connector (X41), cab harness-to-main harness 47-pin connector (X2), and park brake solenoid (Y5) connector for
corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See Cab Harness (W2) Component Location . See Main
Result:
YES:Go to Solenoid Check.

( 2 ) Solenoid Check
Action:
Check resistance of park brake solenoid (Y5). See Electrical Component Specifications . (Group 9015-20.)
Is solenoid resistance within specification?
Result:

NO:Park brake solenoid (Y5) malfunction. Replace solenoid.
Action:
Key switch OFF.

Disconnect park brake solenoid (Y5).
Using a multimeter, check continuity of wire T03 BLU between pin P of EMU J1 connector (X41) and park brake solenoid (Y5)
connector.
Result:

NO:Open circuit in wire T03 BLU. Repair or replace wire. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3) Wiring
Diagram . (Group 9015-10.)
Action:
Check wire G01 BLK for continuity to ground at park brake solenoid (Y5) connector.
Result:

NO:Open circuit in wire G01 BLK. Repair or replace wire. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3) Wiring
Action:
Key switch OFF.

Park brake solenoid (Y5) disconnected.
Turn key switch ON.
Check for voltage on wire T03 BLU at pin P of EMU J1 connector (X41).
Result:
Action:

any damage, corrosion, or debris that could cause short to power condition for T03 BLU wire.
Result:

9015-10.)
Action:
Check for continuity between pin P (wire T03 BLU) of EMU J1 connector (X41) and other pins in same connector.
Result:
NO:Checks complete.
522379.06- Park Brake Release Output Out of Range High

239
Excessive current draw in park brake solenoid (Y5) circuit exceeding driver limit, possibly a short to ground or shorted solenoid.
Park Brake Release Output Out of Range High Diagnostic Procedure

Action:
Key switch OFF.

Result:

Action:
Check resistance of park brake solenoid (Y5). See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:Park brake solenoid (Y5) malfunction. Replace solenoid.
Action:
Key switch OFF.

Using a multimeter, check for continuity to ground at pins 1 and 2 of park brake solenoid (Y5).
Result:
YES:Short to ground within solenoid. Replace park brake solenoid (Y5).

Action:
Key switch OFF.

Using a multimeter, check for continuity to ground at pin P (wire T03 BLU) of EMU J1 connector (X41).
Result:
NO:Checks complete.
522398.02- Park Brake Run Switch Input Erratic or Bad Data

239
Park brake release and park brake run inputs from park brake switch (S2) to engagement and monitor unit (EMU) are an invalid
combination.
Park Brake Release Input Erratic or Bad Data Diagnostic Procedure

Action:

Result:

( 2 ) Switch Check
Action:
Key switch OFF.

Result:

Action:
Key switch OFF.

Check continuity of wire T01 BLU between pin F of EMU J2 connector (X42) and park brake switch (S2) connector.
Result:

NO:Open circuit in wiring harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

Check for continuity between pin F (wire T01 BLU) and pin K (wire T02 BLU) of EMU J2 connector (X42).
Result:
YES:Short circuit in wiring harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

Result:
Action:
Key switch OFF.

Turn key switch ON.
Result:
YES:Short to power in wiring harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
NO:Checks complete.
522398.04- Park Brake Run Switch Input Out of Range Low

239
Park brake release input out of range/low. Park brake release input has short to ground or open circuit.
Park Brake Release Input Out of Range Low Diagnostic Procedure

Action:

Result:

( 2 ) Switch Check
Action:
Key switch OFF.

Result:

Action:
Key switch OFF.

Result:
YES:Open circuit in wiring harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

Result:
NO:Checks complete.
522820.05- High Flow Driver Out of Range Low

239
Open circuit or short to power (with driver off) in circuit to high flow solenoid (Y7).
High Flow Driver Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J1 connector (X41), cab harness-to-main harness 47-pin connector (X2), and high flow solenoid (Y7) connector for
Result:

Action:
Check resistance of high flow solenoid (Y7). See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:High flow solenoid (Y7) malfunction. Replace solenoid.
Action:
Key switch OFF.

Disconnect high flow solenoid (Y7).
Using a multimeter, check continuity of wire H03 GRN between pin S of EMU J1 connector (X41) and high flow solenoid (Y7)
connector.
Result:

NO:Open circuit in wire H03 GRN. Repair or replace wire. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3)
Action:
Check wire G31 BLK for continuity to ground at high flow solenoid (Y7) connector.
Result:

NO:Open circuit in wire G31 BLK. Repair or replace wire. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3) Wiring
Action:
Key switch OFF.

High flow solenoid (Y7) disconnected.
Turn key switch ON.
Check for voltage on wire H03 GRN at pin S of EMU J1 connector (X41).
Result:
Action:

any damage, corrosion, or debris that could cause short to power condition for H03 GRN wire.
Result:

9015-10.)
Action:
Check for continuity between pin S (wire H03 GRN) of EMU J1 connector (X41) and other pins in same connector.
Result:
NO:Checks complete.
522820.06- High Flow Driver Out of Range High

239
Excessive current draw in high flow solenoid (Y7) circuit exceeding driver limit, possibly a short to ground or shorted solenoid.
High Flow Driver Out of Range High Diagnostic Procedure

Action:
Key switch OFF.

Result:

Action:
Check resistance of high flow solenoid (Y7). See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:High flow solenoid (Y7) malfunction. Replace solenoid.
Action:
Key switch OFF.

Using a multimeter, check for continuity to ground at pins A and B of high flow solenoid (Y7).
Result:
YES:Short to ground within solenoid. Replace high flow solenoid (Y7).

Action:
Key switch OFF.

Disconnect EMU J1 connector (X41),
Using a multimeter, check for continuity to ground at pin S (wire H03 GRN) of EMU J1 connector (X41).
Result:
NO:Checks complete.
522826.04- VSF Purge Switch Input Out of Range Low

239
Input signal for selecting manual mode from reversing fan switch (S35) shorted to ground.
VSF Purge Switch Input Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J2 connector (X42) and reversing fan switch (S35) connector for corrosion, loose fit, bent/pushed out terminals or
Result:

Action:
Key switch OFF.

Disconnect reversing fan switch (S35).
Using a multimeter, check for continuity to ground at pin C (wire E41 WHT) of EMU J2 connector (X42).
Result:
( 3 ) Switch Check
Action:
Key switch OFF.

Push reversing fan switch (S35) to MANUAL position and check continuity through switch. In MANUAL position, switch should
have continuity between pins 2 and 3 and between pins 5 and 6.
Result:

Action:
Key switch OFF.

Check for continuity to ground at pins 5 and 6 of reversing fan switch (S35).
Result:

NO:Checks complete.
522827.04- VSF Auto Switch Input Out of Range Low

239
Input signal for selecting auto mode from reversing fan switch (S35) shorted to ground.
VSF Purge Switch Input Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J2 connector (X42) and reversing fan switch (S35) connector for corrosion, loose fit, bent/pushed out terminals or
Result:

Action:
Key switch OFF.

Disconnect reversing fan switch (S35).
Using a multimeter, check for continuity to ground at pin D (wire E40 WHT) of EMU J2 connector (X42).
Result:
( 3 ) Switch Check
Action:
Key switch OFF.

Push reversing fan switch (S35) to AUTO position and check continuity through switch. In AUTO position, switch should have
continuity between pins 2 and 3 only.
Result:

Action:
Key switch OFF.

Check for continuity to ground at pins 2 and 3 of reversing fan switch (S35).
Result:

NO:Checks complete.
522828.04- Creep Mode Switch Input Out of Range Low

239
Input from creep mode switch (S36) shorted to ground.
Creep Mode Switch Input Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J2 connector (X42) and creep mode switch (S36) connector for corrosion, loose fit, bent/pushed out terminals or
Result:

Action:
Key switch OFF.

Disconnect creep mode switch (S36).
Using a multimeter, check for continuity to ground at pin L (wire T06 BLU) of EMU J2 connector (X42).
Result:
( 3 ) Switch Check
Action:
Key switch OFF.

Creep mode switch (S36) disconnected.
Press creep mode switch (S36) and check continuity through switch. When pressed, switch should have continuity between
pins 2 and 3.
Result:

NO:Replace creep mode switch (S36).
Action:
Key switch OFF.

Creep mode switch (S36) disconnected.
Check for continuity to ground at pins 2 and 3 of creep mode switch (S36).
Result:

NO:Checks complete.
522859.04- Lap Bar Switch Input Out of Range Low

239
Input from interlocking seat bar switch (S5) is shorted to ground.
Lap Bar Switch Input Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J2 connector (X42) and interlocking seat bar switch (S5) connector for corrosion, loose fit, bent/pushed out
terminals or crimp malfunctions. See Cab Harness (W2) Component Location . (Group 9015-10.)
Result:

Action:
Key switch OFF.

Disconnect interlocking seat bar switch (S5).
Using a multimeter, check for continuity to ground at pin G (wire M09 PUR) of EMU J2 connector (X42).
Result:
( 3 ) Switch Check
Action:
Key switch OFF.

Interlocking seat bar switch (S5) disconnected.
Lower interlocking seat bar. Check continuity through switch between pins A and B of interlocking seat bar switch (S5)
connector (switch side).
Does switch continuity check OK? (Continuity with little resistance when switch is actuated.)
Result:

NO:Replace interlocking seat bar switch (S5).
Action:
Key switch OFF.

Interlocking seat bar switch (S5) disconnected.
Check for continuity to ground at pins A and B of interlocking seat bar switch (S5) connector (switch side).
Result:

NO:Checks complete.
523217.06- Hydraulic Valve Power 3 Out of Range High

239
Measured output current above maximum, possibly a short to ground.
Hydraulic Valve Power 3 Out of Range High Diagnostic

Procedure—Manual Control Machines
→NOTE:
Hydraulic valve power 1 and 3 are both supplied from same source on EMU: Pin H of EMU J1 connector
(X41). Diagnostic trouble code (DTC) 523219.06 for hydraulic valve power 1 may also be active.
Action:
Check the following connectors for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions:
Engagement and monitor unit (EMU) J1 connector (X41)

Cab harness-to-main harness 47-pin connector (X2)
Main harness-to-hydraulic valve harness 6-pin connector (X4)
Boom spool lock solenoid (Y2) connector
Bucket spool lock solenoid (Y3) connector
Port lock solenoid (Y4) connector
See Cab Harness (W2) Component Location . See Main Harness (W3) Component Location . See Hydraulic Valve Harness (W10)
Result:

Action:
Key switch OFF.

Disconnect boom spool lock solenoid (Y2) connector.
Disconnect bucket spool lock solenoid (Y3) connector.
Disconnect port lock solenoid (Y4) connector.
Using a multimeter, check for continuity to ground at pin H (wire H01 DK GRN) of EMU J1 connector (X41).
Result:
(W3) Wiring Diagram . See Hydraulic Valve Harness (W10) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

Boom spool lock solenoid (Y2) connector disconnected.
Bucket spool lock solenoid (Y3) connector disconnected.
Port lock solenoid (Y4) connector disconnected.

Check for continuity between pin H (wire H01 DK GRN) of EMU J1 connector (X41) and other pins in same connector.
Result:
Wiring Diagram . See Hydraulic Valve Harness (W10) Wiring Diagram . (Group 9015-10.)
NO:Checks complete.
Hydraulic Valve Power 3 Out of Range High Diagnostic Procedure—EH

Control Machines
→NOTE:
Action:
Check engagement and monitor unit (EMU) J1 connector (X41), cab harness-to-main harness 47-pin connector (X2), and
hydraulic control unit (HCU) connectors (X44) and (X46) for corrosion, loose fit, bent/pushed out terminals or crimp
malfunctions. See Cab Harness (W2) Component Location . See Main Harness (W3) Component Location . (Group 9015-10.)
Result:

Action:
Key switch OFF.

Disconnect HCU J1 connector (X44).
Using a multimeter, check for continuity to ground at pin H (wire P32 PNK) of EMU J1 connector (X41).
Result:
Action:
Key switch OFF.

HCU J1 connector (X44) disconnected.
Check for continuity between pin H (wire P32 PNK) of EMU J1 connector (X41) and other pins in same connector.
Result:
Action:
Check for continuity between pin H4 (wire P32 PNK) of HCU J1 connector (X44) and other pins in same connector.
Result:
NO:Checks complete.
523218.06- Propel Valve Power 2 to HCU Out of Range High

239
Measured output current above maximum, possibly a short to ground.
Propel Valve Power 2 to HCU Out of Range High Diagnostic Procedure

Action:
hydraulic control unit (HCU) J2 connector (X45) for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See
Result:

Action:
Key switch OFF.

Using a multimeter, check for continuity to ground at pin F (wire P33 PNK) of EMU J3 connector (X43).
Result:
Action:
Key switch OFF.

Check for continuity between pin F (wire P33 PNK) of EMU J3 connector (X43) and other pins in same connector.
Result:
Action:
Check for continuity between pin L4 (wire P33 PNK) of HCU J2 connector (X45) and other pins in same connector.
Result:

NO:Checks complete.
523219.06- Hydraulic Valve Power 1 Out of Range High

239
Measured output current above current limit, possibly a short to ground.
Hydraulic Valve Power 1 Out of Range High Diagnostic

Procedure—Manual Control Machines
→NOTE:
Action:
Check the following connectors for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions:
Engagement and monitor unit (EMU) J1 connector (X41)

Cab harness-to-main harness 47-pin connector (X2)
Main harness-to-hydraulic valve harness 6-pin connector (X4)
Boom spool lock solenoid (Y2) connector
Bucket spool lock solenoid (Y3) connector
Port lock solenoid (Y4) connector
See Cab Harness (W2) Component Location . See Main Harness (W3) Component Location . See Hydraulic Valve Harness (W10)
Result:

Action:
Key switch OFF.

Disconnect boom spool lock solenoid (Y2) connector.
Disconnect bucket spool lock solenoid (Y3) connector.
Disconnect port lock solenoid (Y4) connector.
Using a multimeter, check for continuity to ground at pin H (wire H01 DK GRN) of EMU J1 connector (X41).
Result:
(W3) Wiring Diagram . See Hydraulic Valve Harness (W10) Wiring Diagram . (Group 9015-10.)
Action:
Key switch OFF.

Boom spool lock solenoid (Y2) connector disconnected.
Bucket spool lock solenoid (Y3) connector disconnected.
Port lock solenoid (Y4) connector disconnected.

Check for continuity between pin H (wire H01 DK GRN) of EMU J1 connector (X41) and other pins in same connector.
Result:
Wiring Diagram . See Hydraulic Valve Harness (W10) Wiring Diagram . (Group 9015-10.)
NO:Checks complete.
Hydraulic Valve Power 1 Out of Range High Diagnostic Procedure—EH

Control Machines
→NOTE:
Action:
hydraulic control unit (HCU) connectors (X44) and (X46) for corrosion, loose fit, bent/pushed out terminals or crimp
malfunctions. See Cab Harness (W2) Component Location . See Main Harness (W3) Component Location . (Group 9015-10.)
Result:

Action:
Key switch OFF.

Using a multimeter, check for continuity to ground at pin H (wire P32 PNK) of EMU J1 connector (X41).
Result:
Action:
Key switch OFF.

Check for continuity between pin H (wire P32 PNK) of EMU J1 connector (X41) and other pins in same connector.
Result:
Action:
Result:
NO:Checks complete.
523693.03- Aux Hyd Channel 1 Input Out of Range High

239
Auxiliary hydraulic control channel 1 input from auxiliary proportional switch (B15) is above maximum valid input or shorted to
power.
Aux Hyd Channel 1 Input High Diagnostic Procedure—Manual Control

Machines
Action:
Key switch OFF.

Turn key switch ON.
Using a multimeter, check for voltage on wire H20 GRN between pin E of EMU J3 connector (X43) and machine ground.
Result:
Action:

to power condition for H20 GRN wire.
Result:

( 3 ) Wire Check
Action:
Key switch OFF.

Using a multimeter, check for continuity between pin E (wire H20 GRN) of EMU J3 connector (X43) and other pins in same
connector.
Result:
NO:Auxiliary proportional switch (B15) malfunction. Replace switch.
Aux Hyd Channel 1 Input High Diagnostic Procedure—EH Control

Machines
Action:
Key switch OFF.

Turn key switch ON.
Using a multimeter, check for voltage on wire H20 GRN between pin E of EMU J3 connector (X43) and machine ground.
Result:
Action:

short to power condition for H20 GRN wire.
Result:

( 3 ) Wire Check
Action:
Key switch OFF.

Using a multimeter, check for continuity between pin E (wire H20 GRN) of EMU J3 connector (X43) and other pins in same
connector.
Result:
NO:Auxiliary proportional switch (B15) malfunction. Replace switch. See Joystick Disassemble and Assemble . (Group 9015-20.)
523693.04- Aux Hyd Channel 1 Input Out of Range Low

239
Auxiliary hydraulic control channel 1 input from auxiliary proportional switch (B15) is open or below minimum valid input.
Aux Hyd Channel 1 Input Low Diagnostic Procedure—Manual Control

Machines
Action:
Key switch OFF.

Result:

Action:
Key switch OFF.

Using a multimeter, check continuity of wire H20 GRN between pin E of EMU J3 connector (X43) and right control lever 12-pin
connector (X22).
Result:

Action:
Check for continuity to ground at pin E (wire H20 GRN) of EMU J3 connector (X43).
Result:
Aux Hyd Channel 1 Input Low Diagnostic Procedure—EH Control

Machines
Action:
Key switch OFF.

Result:

Action:
Key switch OFF.

Using a multimeter, check continuity of wire H20 GRN between pin E of EMU J3 connector (X43) and right control lever 12-pin
connector (X22).
Result:

NO:Open circuit in wire harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
Action:
Check for continuity to ground at pin E (wire H20 GRN) of EMU J3 connector (X43).
Result:
523694.03- Aux Hyd Channel 2 Input Out of Range High

239
Auxiliary hydraulic control channel 2 input from auxiliary proportional switch (B15) is above maximum valid input or shorted to
power.
Aux Hyd Channel 2 Input High Diagnostic Procedure—Manual Control

Machines
Action:
Key switch OFF.

Turn key switch ON.
Using a multimeter, check for voltage on wire H21 GRN between pin D of EMU J3 connector (X43) and machine ground.
Result:
Action:

to power condition for H21 GRN wire.
Result:

( 3 ) Wire Check
Action:
Key switch OFF.

Using a multimeter, check for continuity between pin D (wire H21 GRN) of EMU J3 connector (X43) and other pins in same
connector.
Result:
Aux Hyd Channel 2 Input High Diagnostic Procedure—EH Control

Machines
Action:
Key switch OFF.

Turn key switch ON.
Using a multimeter, check for voltage on wire H21 GRN between pin D of EMU J3 connector (X43) and machine ground.
Result:
Action:

short to power condition for H21 GRN wire.
Result:

( 3 ) Wire Check
Action:
Key switch OFF.

Using a multimeter, check for continuity between pin D (wire H21 GRN) of EMU J3 connector (X43) and other pins in same
connector.
Result:
523694.04- Aux Hyd Channel 2 Input Out of Range Low

239
Auxiliary hydraulic control channel 2 input from auxiliary proportional switch (B15) is open or below minimum valid input.
Aux Hyd Channel 2 Input Low Diagnostic Procedure—Manual Control

Machines
Action:
Key switch OFF.

Result:

Action:
Key switch OFF.

Using a multimeter, check continuity of wire H21 GRN between pin D of EMU J3 connector (X43) and right control lever 12-pin
connector (X22).
Result:

Action:
Check for continuity to ground at pin D (wire H21 GRN) of EMU J3 connector (X43).
Result:
Aux Hyd Channel 2 Input Low Diagnostic Procedure—EH Control

Machines
Action:
Key switch OFF.

Result:

Action:
Key switch OFF.

Using a multimeter, check continuity of wire H21 GRN between pin D of EMU J3 connector (X43) and right joystick 12-pin
connector (X22).
Result:

NO:Open circuit in wire harness. Repair or replace harness. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
Action:
Check for continuity to ground at pin D (wire H21 GRN) of EMU J3 connector (X43).
Result:
523694.12- Aux Hyd Channel 2 Input Device Fault
239
Auxiliary hydraulic control channel 2 input does not compare proportionally to channel 1 input.
Aux Hyd Channel 2 Input Device Fault Diagnostic Procedure

( 1 ) Code Check
Action:
Turn key switch ON.

Using Service ADVISOR ™ or engagement and monitor unit (EMU), clear diagnostic trouble codes (DTCs).
Cycle key switch. Operate machine hydraulics using auxiliary proportional switch (B15). Does DTC return?
Result:
YES:Auxiliary proportional switch (B15) malfunction. Replace switch.

NO:DTC is intermittent. If DTC reoccurs, replace auxiliary proportional switch (B15).
523822.04- High Flow Switch Input Out of Range Low

239
Input from high flow switch (S8) shorted to ground.
High Flow Switch Input Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J3 connector (X43) and high flow switch (S8) connector for corrosion, loose fit, bent/pushed out terminals or crimp
Result:

Action:
Key switch OFF.

Disconnect high flow switch (S8).
Using a multimeter, check for continuity to ground at pin M (wire H02 GRN) of EMU J3 connector (X43).
Result:
( 3 ) Switch Check
Action:
Key switch OFF.

High flow switch (S8) disconnected.
Press high flow switch (S8) and check continuity through switch. When pressed, switch should have continuity between pins 2
and 3.
Result:

NO:Replace high flow switch (S8).
Action:
Key switch OFF.

High flow switch (S8) disconnected.
Check for continuity to ground at pins 2 and 3 of high flow switch (S8).
Result:

NO:Checks complete.
523917.05- Two Speed Output Out of Range Low
239
Open circuit to two speed solenoid (Y6) leading to low or no current to the load.
Two Speed Output Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J1 connector (X41), cab harness-to-main harness 47-pin connector (X2), and two speed solenoid (Y6) connector for
Result:

Action:
Check resistance of two speed solenoid (Y6). See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:Two speed solenoid (Y6) malfunction. Replace solenoid.
Action:
Key switch OFF.

Disconnect two speed solenoid (Y6).
Using a multimeter, check continuity of wire T05 BLU between pin N of EMU J1 connector (X41) and two speed solenoid (Y6)
connector.
Check continuity of wire R03 BLK between pin M of EMU J1 connector (X41) and two speed solenoid (Y6) connector.
Result:
NO:Open circuit in wire harness. Repair or replace wire. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3) Wiring
523917.06- Two Speed Output Out of Range High

239
Excessive current exceeding driver limit, possibly a short to ground, shorted two speed solenoid (Y6), or return current is high
compared to the expected value.
Two Speed Output Out of Range High Diagnostic Procedure

Action:
Key switch OFF.

Result:

Action:
Check resistance of two speed solenoid (Y6). See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:Two speed solenoid (Y6) malfunction. Replace solenoid.
Action:
Key switch OFF.

Two speed solenoid (Y6) disconnected.
Using a multimeter, check for continuity to ground at pins 1 and 2 of two speed solenoid (Y6).
Result:
YES:Short to ground within solenoid. Replace two speed solenoid (Y6).

Action:
Key switch OFF.

Using a multimeter, check for continuity to ground at pin N (wire T05 BLU) of EMU J1 connector (X41).
Result:

Action:
Key switch OFF.

Turn key switch ON.
Check for voltage on wire R03 BLK at pin M of EMU J1 connector (X41).
Result:
Action:

any damage, corrosion, or debris that could cause short to power condition for R03 BLK wire.
Result:

9015-10.)
Action:
Check for continuity between pin M (wire R03 BLK) of EMU J1 connector (X41) and other pins in same connector.
Result:
NO:Checks complete.
523935.05- Aux Hyd Extend Output Out of Range Low

239
Open circuit to auxiliary port (male) solenoid (Y23) causing low or no current, or return current is low compared to expected
value.
→NOTE:
Wire harness tags for solenoids (Y23) and (Y24) may be incorrect.
Auxiliary port (male) solenoid (Y23) (H34 GRN) is left auxiliary solenoid. Auxiliary port (female) solenoid
(Y24) (H35 GRN) is right auxiliary solenoid.
Aux Hyd Extend Output Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J3 connector (X43), cab harness-to-main harness 47-pin connector (X2), and auxiliary port (male) solenoid (Y23)
connector for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See Cab Harness (W2) Component Location
. See Main Harness (W3) Component Location . (Group 9015-10.)
Result:

Action:
Check resistance of auxiliary port (male) solenoid (Y23). See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:Auxiliary port (male) solenoid (Y23) malfunction. Replace solenoid.
Action:
Key switch OFF.

Disconnect auxiliary port (male) solenoid (Y23).
Using a multimeter, check continuity of wire H34 GRN between pin G of EMU J3 connector (X43) and auxiliary port (male)
Check continuity of wire R38 BLK between pin B of EMU J3 connector (X43) and auxiliary port (male) solenoid (Y23) connector.
Result:

Action:
Key switch OFF.

Auxiliary port (male) solenoid (Y23) disconnected.
Check for continuity to ground at pin B (wire R38 BLK) of EMU J3 connector (X43).
Result:
YES:Short to ground in wire R38 BLK. Repair or replace wire. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3)
NO:Checks complete.
523935.06- Aux Hyd Extend Output Out of Range High

239
Excessive current exceeding driver limit, possibly a short to ground, shorted auxiliary port (male) solenoid (Y23), or return
current is high compared to the expected value.
→NOTE:
Aux Hyd Extend Output Out of Range High Diagnostic Procedure

Action:
Key switch OFF.

Result:

Action:
Check resistance of auxiliary port (male) solenoid (Y23). See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:Auxiliary port (male) solenoid (Y23) malfunction. Replace solenoid.
Action:
Key switch OFF.

Using a multimeter, check for continuity to ground at pins 1 and 2 of auxiliary port (male) solenoid (Y23).
Result:
YES:Short to ground within solenoid. Replace auxiliary port (male) solenoid (Y23).
Action:
Key switch OFF.

Using a multimeter, check for continuity between pin G (wire H34 GRN) and pin B (wire R38 BLK) of EMU J3 connector (X43).
Result:
Action:
Key switch OFF.

Using a multimeter, check for continuity to ground at pin G (wire H34 GRN) of EMU J3 connector (X43).
Result:
Action:
Key switch OFF.

Turn key switch ON.
Check for voltage on wire R38 BLK at pin B of EMU J3 connector (X43).
Result:
Action:

connector for any damage, corrosion, or debris that could cause short to power condition for R38 BLK wire.
Result:

9015-10.)
Action:
Check for continuity between pin B (wire R38 BLK) of EMU J3 connector (X43) and other pins in same connector.
Result:
NO:Checks complete.
523941.05- Aux Hyd Retract Output Out of Range Low

239
Open circuit to auxiliary port (female) solenoid (Y24) causing low or no current, or return current is low compared to expected
value.
→NOTE:
Aux Hyd Retract Output Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J3 connector (X43), cab harness-to-main harness 47-pin connector (X2), and auxiliary port (female) solenoid (Y24)
Result:

Action:
Check resistance of auxiliary port (female) solenoid (Y24). See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:Auxiliary port (female) solenoid (Y24) malfunction. Replace solenoid.
Action:
Key switch OFF.

Disconnect auxiliary port (female) solenoid (Y24).
Using a multimeter, check continuity of wire H35 GRN between pin H of EMU J3 connector (X43) and auxiliary port (female)
Check continuity of wire R38 BLK between pin B of EMU J3 connector (X43) and auxiliary port (female) solenoid (Y24)
connector.
Result:

Action:
Key switch OFF.

Auxiliary port (female) solenoid (Y24) disconnected.
Check for continuity to ground at pin B (wire R38 BLK) of EMU J3 connector (X43).
Result:
YES:Short to ground in wire R38 BLK. Repair or replace wire. See Cab Harness (W2) Wiring Diagram . See Main Harness (W3)
NO:Checks complete.
523941.06- Aux Hyd Retract Output Out of Range High

239
Excessive current exceeding driver limit, possibly a short to ground, shorted auxiliary port (female) solenoid (Y24), or return
current is high compared to the expected value.
→NOTE:
Aux Hyd Retract Output Out of Range High Diagnostic Procedure

Action:
Key switch OFF.

Result:

Action:
Check resistance of auxiliary port (female) solenoid (Y24). See Electrical Component Specifications . (Group 9015-20.)
Result:

NO:Auxiliary port (female) solenoid (Y24) malfunction. Replace solenoid.
Action:
Key switch OFF.

Using a multimeter, check for continuity to ground at pins 1 and 2 of auxiliary port (female) solenoid (Y24).
Result:
YES:Short to ground within solenoid. Replace auxiliary port (female) solenoid (Y24).
Action:
Key switch OFF.

Using a multimeter, check for continuity between pin H (wire H35 GRN) and pin B (wire R38 BLK) of EMU J3 connector (X43).
Result:
Action:
Key switch OFF.

Using a multimeter, check for continuity to ground at pin H (wire H35 GRN) of EMU J3 connector (X43).
Result:
Action:
Key switch OFF.

Turn key switch ON.
Check for voltage on wire R38 BLK at pin B of EMU J3 connector (X43).
Result:
Action:

connector for any damage, corrosion, or debris that could cause short to power condition for R38 BLK wire.
Result:

9015-10.)
Action:
Check for continuity between pin B (wire R38 BLK) of EMU J3 connector (X43) and other pins in same connector.
Result:
NO:Checks complete.
524225.04- Remote Start Input Out of Range Low
239
Remote start input short to ground.
Remote Start Input Out of Range Low Diagnostic Procedure

Action:
Key switch OFF.

Check EMU J3 connector (X43), cab harness-to-main harness 47-pin connector (X2), and remote start box 4-pin connector (X10)
for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See Cab Harness (W2) Component Location . See Main
Result:

Action:
Key switch OFF.

Disconnect remote start box.
Using a multimeter, check for continuity to ground at pin L (wire E32 WHT) of EMU J3 connector (X43).
Result:
NO:Checks complete.
524264.11- Checksum Error Unknown Fault
239
Checksum error when writing to EEPROM. Cycle power to release.
Checksum Error Unknown Fault Diagnostic Procedure

( 1 ) Controller Check
Action:
Program engagement and monitor unit (EMU) with correct software.

Operate machine and check for DTCs.
Does DTC return?
Result:
YES:Engagement and monitor unit (EMU) malfunction. Replace EMU.
OPERATIONAL CHECKOUT PROCEDURE (g) by Belgreen v2.0
NO:Checks complete.
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE

Table of contents
Group 10 - Operational Checkout Procedure ....................................................................................... 1
Key Switch ON, Engine ON Checks ....................................................................................................... 1

Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10: Operational Checkout Procedure
Group 10 - Operational Checkout Procedure

Operational Checkout
Use this procedure to make a quick check of machine operation by doing a walk around inspection and performing specific
checks from operator’s seat.
Complete visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring, etc.) before performing
checkout.
Most checks will require machine systems to be at normal operating temperatures and a level area with adequate space to
operate machine. Some checks may require varied surfaces.
No special tools are necessary to perform the checkout.
If no problem is found, go to next check. If problem is indicated, an additional check or repair procedure will be suggested.
Key Switch OFF, Engine OFF Checks

( 1 ) Diagnostic Trouble Code Check
Action:
Always check for diagnostic trouble codes and correct them before performing the operational checkout.
Diagnostic trouble codes are displayed on the EMU.
Sit in seat and access diagnostic trouble code menu. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
sss:
Are diagnostic trouble codes present?
Result:
YES:Correct all diagnostic trouble codes. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
NO:Proceed with operational checkout.
( 2 ) Engagement and Monitor Unit (EMU) Circuits Check
Action:
Sit in operator′s seat.

sss:
Do all indicators illuminate and then go out depending on machine status?
sss:
Do all EMU display segments turn on, turn off, display TMC BY DEERE for 2 seconds, display correct machine model and speed
setting for 2 seconds, and then display the hour meter?
Lower interlocking seat bar.

sss:
Do seat and interlocking seat bar indicators go off?
Result:

NO:Check monitor unswitched power 10 amp fuse (F2). See Fuse and Relay Specifications . (Group 9015-10.)
NO:Check seat switch (S4) and interlocking seat bar switch (S5). See Engagement and Monitor Unit Data Items . (Group
9015-16.)
NO:Check EMU circuits. See System Functional Schematic . (Group 9015-10.)
Key Switch ON, Engine OFF Checks

( 1 ) EMU Circuits Check
Action:
Turn key switch ON.

sss:
Do gauges move to the far right position, then move to the center position, and then display the machine status?
sss:
Do switches on instrument panel illuminate?
sss:
Does EMU alarm sound?
Close cab door—if equipped.

sss:
Does the cab door indicator go off?
Result:

NO:Check key switch unswitched power 7.5 amp fuse (F1). See Fuse and Relay Specifications . (Group 9015-10.)
NO:Check monitor unswitched power 10 amp fuse (F2). See Fuse and Relay Specifications . (Group 9015-10.)
NO:Check switched power 10 amp fuse (F15). See Fuse and Relay Specifications . (Group 9015-10.)
NO:Check cab door switch (S13), if equipped. For switch diagnostics, see Engagement and Monitor Unit Data Items . (Group
9015-16.)
NO:Check EMU circuits. See System Functional Schematic . (Group 9015-10.)
( 2 ) Horn Circuit Check (If Equipped)
Action:
Press the horn switch.

sss:
Does horn sound?
Result:

NO:Check horn 10 amp fuse (F16). See Fuse and Relay Specifications . (Group 9015-10.)
NO:Check ignition relay (K8). See Electrical Component Specifications . (Group 9015-20.)
NO:Check key switch (S1). See Electrical Component Checks . (Group 9015-20.)
NO:Check horn circuit. See System Functional Schematic . (Group 9015-10.)
( 3 ) Lights Circuit Check
Action:
Push light switch to middle position.

sss:
Do front work lights and tail lights turn on?
Result:

NO:Check lights 20 amp fuse (F6) (S.N. —233421) or lights 25 amp fuse (F6) (S.N. 233422— ). See Fuse and Relay
Specifications . (Group 9015-10.)

NO:Check work lights switch (S6). See Electrical Component Checks . (Group 9015-20.)
NO:Check accessory relay (K4). See Electrical Component Specifications . (Group 9015-20.)
Action:
Push light switch to upper position.

sss:
Do front work lights and tail lights stay on and rear work light turns on?
Result:

NO:Check light circuit. See System Functional Schematic . (Group 9015-10.)
Action:
If equipped, push dual flasher switch to the upper position.

sss:
Do the dual flashers turn on?
Result:

NO:Check left flasher light inline 5 amp fuse (F10). Check right flasher light inline 5 amp fuse (F11). Check switched power 10
amp fuse (F15). See Fuse and Relay Specifications . (Group 9015-10.)
NO:Check dual flasher relay (K5). See Electrical Component Specifications . (Group 9015-20.)
NO:Check dual flasher switch (S7). See Electrical Component Checks . (Group 9015-20.)
( 4 ) Windshield Wiper Circuit Check (If Equipped)
Action:
Close cab door.

Push windshield wiper and washer switch to the middle position.
sss:
Does wiper operate?
Result:

NO:Check accessory 20 amp fuse (F7). See Fuse and Relay Specifications . (Group 9015-10.)
NO:Check windshield wiper and washer switch (S12). See Electrical Component Checks . (Group 9015-20.)
NO:Check windshield wiper circuit. See System Functional Schematic . (Group 9015-10.)
( 5 ) Windshield Washer Circuit Check (If Equipped)
Action:
Close cab door.

Turn on windshield wiper.
Push and hold windshield wiper and washer switch in the upper position.
IMPORTANT:
Avoid damage to washer motor. Washer motor may be damaged if washer switch is held for more than 20
seconds, or continually operated with no fluid in the washer fluid tank.
sss:
Does washer operate?
Result:

NO:Check washer fluid level.
NO:Check washer hose for kinks or obstructions.
NO:Check accessory 20 amp fuse (F7). See Fuse and Relay Specifications . (Group 9015-10.)
NO:Check windshield wiper and washer switch (S12). See Electrical Component Checks . (Group 9015-20.)
NO:Check windshield washer circuit. See System Functional Schematic . (Group 9015-10.)
Key Switch ON, Engine ON Checks

( 1 ) Engine Start Check
Action:
Position engine speed control dial in slow idle position.

Start engine.
sss:
Does engine speed increase briefly, then return to slow idle?
Result:

NO:Check slow idle and fast idle engine speeds.
( 2 ) Engine Idle Check
Action:
Position engine speed control dial in slow idle position.

sss:
Does engine idle poorly?
Result:
YES:Check water separator fuel filter. See Check and Drain Water Separator Fuel Filter . (Operator′s Manual.)
YES:Test diesel fuel. See Testing Diesel Fuel . (Operator′s Manual.)
YES:Check for air leaks on suction side of air intake system. See Test for Intake Air Leaks . (CTM101019.)
( 3 ) Engine Speed Check
Action:
Set EMU to display engine rpm.

Set engine speed at slow idle with engine speed control dial and engine speed control pedal released.
sss:
Does engine run between 1150—1250 rpm?
Rotate engine speed control dial to set the engine speed at fast idle. Engine speed control pedal must be released.
sss:
329D— Does engine run between 2950—3050 rpm?
sss:
Fully depress engine speed control pedal to set engine speed at fast idle. Engine speed control dial must be in slow idle
position.
sss:
sss:
Result:

NO:Check diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
NO:Check B18 engine speed control dial and B19 engine speed control pedal. See Electrical Component Checks . (Group
9015-20.) See System Functional Schematic . (Group 9015-10.)
( 4 ) Hydraulic Control Enable Check
Action:

Engine speed at slow idle.
Engage park brake.
Actuate boom and bucket functions.
sss:
Do boom and bucket move?
Result:
NO:Continue check.
YES:Check park brake switch (S2). See Electrical Component Checks . (Group 9015-20.)
YES:Check diagnostic trouble codes and check port lock solenoid (Y4). See Reading Diagnostic Trouble Codes (DTCs) . (Group
9015-20.) See Solenoid Test . (Group 9015-20.)
YES:Check diagnostic trouble codes and check boom spool lock solenoid (Y2) and bucket spool lock solenoid (Y3). See Reading
Diagnostic Trouble Codes (DTCs) . (Group 9015-20.) See Solenoid Test . (Group 9015-20.)
Action:
Move park brake switch to the run position to enable hydraulics.

Actuate boom and bucket functions.
sss:
Do boom and bucket move?
Result:

NO:Check park brake switch (S2). See Electrical Component Checks . (Group 9015-20.)
NO:Check diagnostic trouble codes and check port lock solenoid (Y4). See Reading Diagnostic Trouble Codes (DTCs) . (Group
9015-20.) See Solenoid Test . (Group 9015-20.)
NO:Check diagnostic trouble codes and check boom spool lock solenoid (Y2) and bucket spool lock solenoid (Y3). See Reading
Diagnostic Trouble Codes (DTCs) . (Group 9015-20.) See Solenoid Test . (Group 9015-20.)
( 5 ) Electric Quik-Tatch™ Check (If Equipped)
Action:
IMPORTANT:
Avoid damage to Quik-Tatch ™ motor. Damage to Quick-Tatch motor will occur if motor is immersed in
liquid. Do not immerse in liquid.

Press and hold lower part of Quik-Tatch switch to unlock the Quik-Tatch latches.
sss:
Do Quik-Tatch latches release attachment?
Press and hold upper part of Quik-Tatch switch to lock the Quik-Tatch latches.
sss:
Do Quik-Tatch latches secure attachment?
Result:

NO:Check Quik-Tatch inline 30 amp fuse (F13), switched power 10 amp fuse (F15) and accessory 20 amp fuse (F7). See Fuse
and Relay Specifications . (Group 9015-10.)
NO:Check Quik-Tatch switch (S26). See Electrical Component Checks . (Group 9015-20.)
NO:Check Quik-Tatch lock relay (K13) and Quik-Tatch unlock relay (K14). See Electrical Component Specifications . (Group
9015-20.)
( 6 ) Back-Up Alarm Check (If Equipped)
Action:
CAUTION:
Prevent injury from unexpected machine movement. Keep bystanders clear of machine.

Drive machine in reverse.
sss:
Does back-up alarm sound?
Result:

NO:Check H2 back-up alarm. See Electrical Component Checks . (Group 9015-20.)
NO:Check F7 accessory 20 amp fuse and F1 key switch unswitched power 7.5 amp fuse. See Fuse and Relay Specifications .
(Group 9015-10.)
NO:Check S1 key switch. See Electrical Component Checks . (Group 9015-20.)
NO:Check K4 accessory relay. See Electrical Component Specifications . (Group 9015-20.)
NO:Check S10 left reverse switch and S11 right reverse switch. See System Functional Schematic . (Group 9015-10.)
( 7 ) Steering Mistracking Check
Action:
CAUTION:
Engine speed at fast idle.

Drive machine at full speed forward on a flat and level surface for 30.5 m (100 ft.).
Repeat procedure for reverse direction.
Observe which direction and how much the machine mistracks from a straight line.
sss:
Does machine mistrack more than the width of the machine over 30.5 m (100 ft.)?
Result:
YES:Steering levers misadjusted. Check steering lever adjustment. See Steering Lever Adjustment—Centering and Tracking
Adjustment . (Group 9026-25.)
( 8 ) Two Speed Check (If Equipped)
Action:
CAUTION:

Drive machine at full speed forward on a flat and level surface.
Push two speed switch to activate fast speed mode.
Push two speed switch to activate slow speed mode.
sss:
Does machine accelerate then decelerate?
Result:

NO:Check handle switches 5 amp fuse (F17). See Fuse and Relay Specifications . (Group 9015-10.)
NO:Check ignition relay (K8). See Electrical Component Specifications . (Group 9015-20.)
NO:Check two speed switch (S25). See Electrical Component Checks . (Group 9015-20.)
NO:Check two speed electrical circuit. See System Functional Schematic . (Group 9015-10.)
NO:Check two speed solenoid valve (Y6). See Solenoid Test . (Group 9015-20.)
NO:Hydrostatic system malfunction. See Machine Will Not Shift Into Or Out Of High Speed . (Group 9026-15.)
( 9 ) Boom Down Drift Check
Action:
→NOTE:
This check may require two people.
→NOTE:
Machine must be equipped with a bucket for this check.

Operate hydraulic system until hydraulic oil reaches temperature specification.
Item Measurement Specification
Hydraulic Oil Temperature 43°C
110°F
Actuate boom function to lower boom to ground.

Raise boom half way.
Engage park brake.
Mark and record a distance on the boom cylinder rod from the cylinder barrel.
Disengage park brake.
Allow machine to sit with engine speed at slow idle for 5 minutes.
Engage park brake.
Measure marked distance on boom cylinder rod.
Boom Cylinder Drift (maximum) 13 mm/5 min.
0.5 in./5 min.
sss:
Does boom drift down more than specification?
Result:

Action:

Engage park brake.
Turn engine off.
Allow machine to sit for 5 minutes.
0.5 in./5 min.
sss:
Does boom drift down more than specification?
Result:
YES:For troubleshooting information. See Boom Drifts Down . (Group 9025-15.)

( 10 ) Boom Up Drift Check
Action:
→NOTE:
→NOTE:

110°F
→NOTE:
Bucket may need to be in dump position.
Actuate boom down function to raise front of machine off of the ground.

Engage park brake.
Mark and record a distance on the boom cylinder rod from the cylinder barrel.
Engage park brake.
Measure marked distance on boom cylinder rod.
0.5 in./5 min.
sss:
Does boom drift up more than specification?
Result:

Action:

Engage park brake.
Turn engine off.
0.5 in./5 min.
sss:
Does boom drift up more than specification?
Result:
YES:For troubleshooting information. See Boom Drifts Up . (Group 9025-15.)

( 11 ) Bucket Dump Drift Check
Action:
→NOTE:
→NOTE:

110°F

Fully roll back bucket.
Dump bucket half way.
Engage park brake.
Mark and record a distance on the bucket cylinder rod from the cylinder barrel.
Engage park brake.
Measure marked distance on bucket cylinder rod.
Bucket Cylinder Drift (maximum) 13 mm/5 min.
0.5 in./5 min.
sss:
Does bucket drift down more than specification?
Result:

Action:

Fully roll back bucket.
Engage park brake.
Turn engine off.
0.5 in./5 min.
sss:
Does bucket drift down more than specification?
Result:
YES:For troubleshooting information. See Bucket Drifts Down . (Group 9025-15.)

( 12 ) Bucket Curl Drift Check
Action:
→NOTE:
→NOTE:

110°F

Engage park brake.
Mark and record a distance on the bucket cylinder rod from the cylinder barrel.
Engage park brake.
Measure marked distance on bucket cylinder rod.
0.5 in./5 min.
sss:
Does bucket drift up more than specification?
Result:

Action:

Engage park brake.
Turn engine off.
0.5 in./5 min.
sss:
Does bucket drift up more than specification?
Result:
YES:For troubleshooting information. See Bucket Drifts Up . (Group 9025-15.)

( 13 ) Auxiliary Hydraulic Override Check
Action:
CAUTION:
Prevent injury from operating attachments. Stay clear of moving parts on the attachment.

Operate auxiliary hydraulic function.
Raise interlocking seat bar and exit machine.
sss:
Do the auxiliary hydraulics shut off?
Return to seat, lower interlocking seat bar and close cab door—if equipped.
Operate auxiliary hydraulic function.
Press auxiliary hydraulic override switch.
sss:
Does “AUX HYDRAULIC BYPASS” appear in EMU display?
→NOTE:
Operator must exit machine within 15 seconds of pressing auxiliary hydraulic override switch.
Open cab door and exit machine.

sss:
Do the auxiliary hydraulics continue to operate after operator has exited the machine?
Return to seat, lower interlocking seat bar and close cab door, if equipped.
Disengage auxiliary hydraulics.
sss:
Does EMU exit “AUX HYDRAULIC BYPASS” mode and return to last run data item?
Result:

NO:Check auxiliary hydraulic override switch (S21). See Electrical Component Checks . (Group 9015-20.)
NO:Check auxiliary hydraulic override switch logic. See Engagement and Monitor Unit (EMU) Circuit Theory of Operation .
(Group 9015-15.)
( 14 ) Self Leveling Valve Check (If Equipped)
Action:
→NOTE:
Self leveling function is only active for boom up function.

Lower boom to the ground.

Position bottom of bucket on the ground.
Raise boom.
sss:
Does bucket self level as boom is raised?
Result:

NO:Check adjustable orifice screw. See Self Leveling Valve Operation—If Equipped . (Group 9025-05.)
NO:Check valve removed from self leveling valve. See Self Leveling Valve Operation—If Equipped . (Group 9025-05.)
( 15 ) Heating and Air Conditioning System Check
Action:
→NOTE:
Engine will need to be at operating temperature for this check.

Turn blower speed dial from off to slow, medium and high speeds.
sss:
Does fan speed increase and/or decrease as switch is moved?
Turn blower speed dial to medium speed.

Turn cab temperature control dial to hot (red).
sss:
Does warm air come out of air ducts?
Turn cab temperature control dial to cold (blue).

sss:
Does cool air come out of air ducts?
Turn on air conditioner.

sss:
Does cold air come out of air duct after a couple of minutes?
Result:

NO:Check air conditioner and heater 15 amp fuse (F8). See Fuse and Relay Specifications . (Group 9015-10.)
NO:Check blower speed dial (S9). See Electrical Component Checks . (Group 9015-20.)
NO:Check cab temperature control dial (R3). See Electrical Component Checks . (Group 9015-20.) See Heater System Does Not
Operate . (Group 9031-15.)
NO:Check air conditioner switch (S19). See Electrical Component Checks . (Group 9015-20.) See Air Conditioning System Does
Not Operate . (Group 9031-15.)
( 16 ) Cycle Times Check—329D
Action:

ENGINE (g) by Belgreen v2.0
110°F

Record cycle time for each function.
Does machine perform within specification?
Cycle Times
Boom Raise Cycle Time (maximum) 4.2 sec
Boom Lower Cycle Time (maximum) 2.6 sec
Bucket Curl Cycle Time (maximum) 2.4 sec
Bucket Dump Cycle Time (maximum) 1.7 sec
Result:

NO:Check engine speed. See Engine Speed Check , earlier in this checkout.
NO: See Hydraulic Functions Slow Or No Power . (Group 9025-25.)
( 17 ) Cycle Times Check—333D
Action:

110°F

Record cycle time for each function.
Does machine perform within specification?
Cycle Times
Boom Raise Cycle Time (maximum) 4.4 sec
Boom Lower Cycle Time (maximum) 3.2 sec
Bucket Curl Cycle Time (maximum) 2.4 sec
Bucket Dump Cycle Time (maximum) 2.0 sec
Result:
YES:Check complete.
NO:Check engine speed. See Engine Speed Check , earlier in this checkout.
NO: See Hydraulic Functions Slow Or No Power . (Group 9025-25.)
Section 9010 - ENGINE

Table of contents
Group 05 - Theory of Operation ............................................................................................................. 1
John Deere Engine ................................................................................................................................ 1
Cold Start Operation ............................................................................................................................. 2
Group 15 - Diagnostic Information ........................................................................................................ 4
John Deere Engine ................................................................................................................................ 4
Engine Cooling System Component Location ....................................................................................... 5
Engine Fuel System Component Location ............................................................................................ 6
Engine Intake and Exhaust Component Location ................................................................................. 8
Engine Hard to Start or Does Not Start When Cold Diagnostic Procedure ............................................ 9
Group 25 - Tests ..................................................................................................................................... 11
John Deere Engine .............................................................................................................................. 11
Engine Power Test Using Turbocharger Boost Pressure ..................................................................... 12

Section 9010 - ENGINE Group 05: Theory of Operation

John Deere Engine
For more information on John Deere PowerTech ™ engines and components, see the following component technical manual.
See PowerTech™ E 2.4L and 3.0L Diesel Engines . (CTM101019.)
Section 9010 - ENGINE Group 05: Theory of Operation
Cold Start Operation

Glow Plug Operation
All machines are equipped with a glow plug cold weather starting aid system, which consists of the glow plug 60 amp fuse (F9),
a glow plug relay (K2) and glow plugs in each cylinder. The engine control unit (ECU) energizes the glow plug system based on
ambient air temperature, engine coolant temperature, hydraulic oil temperature, and internal ECU temperature. The ECU uses
the coldest of these four temperatures to determine glow plug activation.
When the operator turns the key switch to the RUN or START positions, the ECU determines the amount of glow plug activation
based on temperature as previously described. If the glow plug system is needed, the ECU energizes the glow plug relay (K2),
which sends power to the glow plugs located in each cylinder.
If glow plug system is activated, the engagement and monitor unit (EMU) displays a glow plug icon, text stating Wait to Start,
and the count down of the seconds remaining before the engine should be started.
The ECU keeps the glow plug relay energized for an amount of time that is determined by the measured temperatures.
Glow Plug Activation Time
Lowest Observed Temperature Preheat Time Reheat Time
-20°C
30 seconds 10 seconds
-4°F
-10°C
14°F
-5°C
23°F
0°C
32°F
10°C
50°F
15°C
59°F
16°C
0 seconds 0 seconds
61°F
When the ECU has determined that the preheat time is adequate, it de-energizes the glow plug relay. The glow plug relay
deactivation is delayed 5 seconds from when the EMU stops displaying the Wait to Start text. This delay is to compensate for
the time from when the operator notices the indicator is off and then starts cranking the engine. This delay ensures the glow
plugs are still on or are off very shortly before the engine is cranked. If the operator turns and holds the key switch to the
START position at this time, the engine will crank and start.
Depending on how cold the start temperature is, the ECU can re-energize the glow plug relay once the engine has started to
provide additional glow plug heat during initial engine run up. Once engine speed has reached 800—1000 rpm, the ECU will de-
energize the relay. After the engine has started and reached idle speed, the ECU will have the glow plugs reheat engine for an
additional set amount of time, as needed.
Anytime the engine cranks but does not start, a key switch ON/OFF cycle will be required before preheating is allowed again.
Fan Bypass Operation—(If Equipped)
For better starting in cold weather, machines can be equipped with two fan bypass valves and a check tee fitting.
Both fan bypass solenoid 1 (Y33) and fan bypass solenoid 2 (Y34) are wired in the same circuit from the engine control unit
(ECU) as the glow plug relay (K2). When the ECU energizes the glow plug relay during engine preheat and after engine startup,
both fan bypass solenoids are also energized.
When fan bypass solenoid 1 is energized, the fan bypass spool 1 shifts. This directs charge oil to the check tee fitting.
The check tee fitting has two internal check valves. One check valve is set to open at 35 kPa (0.35 bar) (5 psi) and the other
check valve at 830 kPa (8.3 bar) (120 psi).
Charge oil through the 35 kPa (0.35 bar) (5 psi) check valve directs flow to the hydrostatic pumps, hydraulic fan system, and
hydraulic oil filter manifold.
Charge oil through the 830 kPa (8.3 bar) (120 psi) check valve directs flow to fan bypass solenoid 2. With this solenoid
energized and valve spool shifted, a direct path for charge oil to flow to the hydraulic oil tank is opened.
This direct route to return reduces charge pressure in the system and effectively bypasses the hydraulic fan system and filter,
which reduces engine load for cold weather starting. Charge oil flow through the 35 kPa (0.35 bar) (5 psi) check valve provides
the necessary minimal flow to the hydrostatic pumps at engine startup.
Section 9010 - ENGINE Group 15: Diagnostic Information
Hydraulic Oil Cooler Bypass Operation—(If Equipped)

For machines equipped with the hydraulic oil cooler bypass valve, the hydraulic oil cooler bypass valve allows hydraulic oil flow
to bypass the hydraulic oil cooler when oil flow is restricted due to cold oil or a dirty or plugged hydraulic oil cooler. See
Hydraulic Oil Filter Manifold Operation (Group 9025-05) for more information.

John Deere Engine
Engine Cooling System Component Location
Engine Cooling System Component Location

LEGEND:
1 Fan
2 Coolant Surge Tank
3 Radiator
4 Thermostat Housing-to-Radiator Pipe
5 Radiator-to-Coolant Pump Pipe
6 Thermostat Housing
7 Coolant Pump
8 Radiator Drain Hose
Engine Fuel System Component Location
Engine Fuel System Component Location

LEGEND:
1 Water Separator Fuel Filter
2 Fuel Tank
3 In-Line Fuel Filter
4 Fuel Tank-to-In-Line Fuel Filter Hose
5 In-Line Fuel Filter-to-Fuel Transfer Pump Hose
6 Fuel Transfer Pump
7 Fuel Transfer Pump-to-Water Separator Fuel Filter Hose
8 Water Separator Fuel Filter-to-Fuel Rack Hose
9 Fuel Rack-to-Fuel Tank Hose
B4 Fuel Level Sensor
Engine Fuel System Component Location (if equipped)

LEGEND:
1 Water Separator Fuel Filter
2 Fuel Tank
6 Fuel Transfer Pump
7 Fuel Transfer Pump-to-Water Separator Fuel Filter Hose
8 Water Separator Fuel Filter-to-Fuel Rack Hose
9 Fuel Rack-to-Fuel Tank Hose
10 Fuel Tank-to-Auxiliary Fuel Filter and Water Separator Hose
11 Auxiliary Fuel Filter and Water Separator-to-Fuel Transfer Pump Hose
12 Auxiliary Fuel Filter and Water Separator (if equipped)
Engine Intake and Exhaust Component Location
Engine Intake and Exhaust Component Location

LEGEND:
1 Muffler
2 Air Cleaner Assembly
3 Charge Air Cooler
4 Turbocharger
5 Air Cleaner Assembly-to-Turbocharger Pipe
6 Turbocharger-to-Muffler Pipe
7 Exhaust Manifold
8 Turbocharger-to-Charge Air Cooler Pipe
9 Charge Air Cooler-to-Intake Manifold Pipe
10 Intake Manifold
B1 Air Filter Restriction Switch
B24 Ambient Air Temperature Sensor
Engine Hard to Start or Does Not Start When Cold

66
Engine Hard to Start or Does Not Start When Cold Diagnostic Procedure
( 1 ) Engine Software Check
Action:
→NOTE:
Park brake drag and poor starting performance can occur if ECU software is not at correct version.
Verify that engine control unit (ECU) is programmed with the correct software version.
Is ECU software at correct version
Result:
YES:Go to Cold Start Package Check.

NO:Program engine control unit (ECU) with correct software version.
( 2 ) Cold Start Package Check
Action:
Check if machine is equipped with optional cold start package.

A quick visual check is if block heater is installed in engine. If block heater is installed, machine is equipped with cold start
package.
Is machine equipped with cold start package?
Result:
YES:Go to Block Heater Check.

NO: Go to Engine Cranking Time Check .
( 3 ) Block Heater Check
Action:
Is ambient air temperature below -15°C (5°F)?
Result:

NO: Go to Fan Bypass Valve Check .
Action:
For temperatures below -15°C (5°F), block heater should be used and plugged in for a minimum of 4 hours.
Was block heater plugged in for 4 hours?
Result:
YES:Go to Diesel Fired Coolant Heater Check.

NO:Allow block heater to heat engine for a minimum of 4 hours.
( 4 ) Diesel Fired Coolant Heater Check
Action:
For temperatures below -20°C (-4°F), diesel fired coolant heater should be used and ran for a minimum of 4 hours.
Was diesel fired coolant heater ran for 4 hours?
Section 9010 - ENGINE Group 25: Tests
Result:
YES: Go to Engine Cranking Time Check .

NO:Allow diesel fired coolant heater to run and heat engine for a minimum of 4 hours.
( 5 ) Fan Bypass Valve Check
Action:
Observe hydraulic fan while cranking engine or after engine starts.

Is fan spinning while engine is cranking or within first 60 seconds after engine starts?
Result:
YES:Fan bypass valve malfunction. See Fan Bypass Valve Test . (Group 9025-25.)
NO:Go to Engine Cranking Time Check.
( 6 ) Engine Cranking Time Check
Action:
Record engine coolant temperature as displayed on engagement and monitor unit (EMU).
Record hydraulic oil temperature as displayed on EMU.
Record ambient air temperature.
Cycle ignition power/glow plugs and attempt to start machine. Crank engine until starter times out or engine starts. Record
engine cranking time.
Using the coldest of the three temperatures recorded, use the table, below, to compare model, cranking time and temperature
to evaluate cold start performance.
Cold Start Performance Table
Cold Start 5°C 0°C -5°C -10°C -15°C -20°C -25°C -30°C
Model
Package (41°F) (32°F) (23°F) (14°F) (5°F) (-4°F) (-13°F) (-22°F)
318D, 320D
319D, 323D NO 8 sec. 8 sec. (1) (1) (1) (1) (1) (1)
(4)
318D, 320D
319D, 323D YES 8 sec. 8 sec. 20 sec. 34 sec. 44 sec. 14 sec. (2) 18 sec. (3) 24 sec. (3)
(4)
326D, 328D,
332D, 329D,
NO 8 sec. 8 sec. (1) (1) (1) (1) (1) (1)
333D
(5)
326D, 328D,
332D, 329D,
YES 8 sec. 8 sec. 10 sec. 20 sec. 30 sec. 14 sec. (2) 18 sec. (3) 24 sec. (3)
333D
(5)
(1) Cold start package required.
(2) Block heater required for temperatures below -15°C (5°F). Performance based on block heater plugged in for a minimum of 4 hours.
(3) Diesel fired coolant heater required for temperatures below -20°C (-4°F). Performance based on diesel fired coolant heater run for a minimum of 4 hours.
(4) 318D, 319D, 320D, 323D cold start performance data does not include machines with high flow hydraulics option. High flow hydraulics option will degrade starting
performance and is not included in the table.
(5) 326D, 328D, 329D, 332D, 333D cold start performance data includes machines with high flow hydraulics option.
Does machine cold start performance match table data?
Result:
YES:Checks complete. Normal machine operation.

NO:Contact dealer technical assistance center (DTAC) for further assistance. Include all data obtained during this diagnostic
procedure when contacting DTAC.
Group 25 - Tests
John Deere Engine
Engine Power Test Using Turbocharger Boost Pressure

Specifications
SPECIFICATIONS
88—94°C
Engine Coolant Temperature
190—200°F
326D
Engine Speed Fast Idle 3000 rpm
Engine Speed Rated 2800 rpm
145 kPa at 2800 rpm

Turbocharger Boost Pressure 1.5 bar at 2800 rpm
21 psi at 2800 rpm
328D
152 kPa at 2800 rpm

22 psi at 2800 rpm
329D
152 kPa at 2800 rpm

22 psi at 2800 rpm
332D
145 kPa at 2600 rpm

21 psi at 2600 rpm
333D
145 kPa at 2600 rpm

21 psi at 2600 rpm
his procedure should only be used as a general guide to determine engine condition and power level.
[1] - Raise and block machine. See Raising and Blocking Machine . (Operator′s Manual.)
[2] - Raise cab. See Raising Operator′s Station . (Operator′s Manual.)
[3] -
LEGEND:
1 Pipe Plug
Manifold Pressure Test Connection

Remove pipe plug (1) from engine rocker arm cover.
[4] - Connect hose from JDE147 Manifold Pressure Test Kit or KFM10002 Universal Pressure Test Kit to tee fitting. Route the
hose and gauge in to cab so that hose is not pinched when cab is lowered.
[5] - Lower cab.
[6] -
IMPORTANT:
Engine must be at operating temperature to develop full power.
Before checking turbo boost pressure, warm up engine to allow the lubricating oil to reach operating temperature.
Engine Coolant Temperature 88—94°C
190—200°F
[7] - Run engine at specification and set the engagement and monitor unit to display engine RPM. See Engagement and
Monitor Unit Operation . (Group 9015-20.)
326D
328D
329D
332D
333D
[8] -
CAUTION:
Prevent possible injury from unexpected machine movement. Perform test in an open area clear of
objects and bystanders.
→NOTE:
For accurate test results, the machine wheels or tracks cannot spin during the test procedure.
Pull engine down to rated engine speed during test using the appropriate procedure based on machine model:
326D
328D
329D
332D
333D
326D, 328D, 329D, 332D, 333D Manual Control Machines:
Cap hydrostatic lines between hydrostatic pumps and motors.
326D, 328D, 329D, 332D EH Control Machines (Single Speed):
ELECTRICAL SYSTEM (g) by Belgreen v2.0
Cap hydrostatic lines between hydrostatic pumps and motors.
326D, 328D, 329D, 332D, 333D EH Control Machines (Two Speed):
Engage high speed. Push against an immovable object, such as a loading dock.
[9] - Repeat procedure three times and record highest pressure reading. Compare results with specification.
326D
Turbocharger Boost Pressure 145 kPa at 2800 rpm
1.5 bar at 2800 rpm
21 psi at 2800 rpm
328D
1.5 bar at 2800 rpm
22 psi at 2800 rpm
329D
1.5 bar at 2800 rpm
22 psi at 2800 rpm
332D
1.5 bar at 2600 rpm
21 psi at 2600 rpm
333D
1.5 bar at 2600 rpm
21 psi at 2600 rpm
→NOTE:
Reduce boost pressure specification by 7% if No. 1 fuel is used.
[10] - Check the following if turbocharger boost pressure is low:
Incorrect fuel
Restricted air cleaner element
Restricted fuel filter element
Incorrect fast idle adjustment
Exhaust manifold leaks
Low compression pressure
Cam lobe wear (valve clearance)
Carbon build-up in turbocharger and muffler
Faulty injectors
Turbocharger compressor or turbine wheel rubbing housing
Section 9015 - ELECTRICAL SYSTEM

Table of contents
Group 05 - System Information ............................................................................................................. 1
Electrical Diagram Information ............................................................................................................. 1
Electrical Schematic Symbols ............................................................................................................... 5
Group 10 - System Diagrams ................................................................................................................. 8
Fuse and Relay Specifications .............................................................................................................. 8
System Functional Schematic, Wiring Diagram and Component Location Master Legend ................. 12
System Functional Schematic ............................................................................................................. 17
Engine Harness (W1) Component Location ........................................................................................ 30
Engine Harness (W1) Wiring Diagram ................................................................................................ 31
Cab Harness (W2) Component Location ............................................................................................. 33
Cab Harness (W2) Wiring Diagram ..................................................................................................... 35
Main Harness (W3) Component Location ............................................................................................ 40
Main Harness (W3) Wiring Diagram .................................................................................................... 44
Reverse Switch Harness (W4) Component Location ........................................................................... 57
Reverse Switch Harness (W4) Wiring Diagram ................................................................................... 58
Dual Flasher Harness (W5) Component Location ............................................................................... 59
Dual Flasher Harness (W5) Wiring Diagram ....................................................................................... 62
Control Lever Harness (W6) Component Location .............................................................................. 65
Control Lever Harness (W6) Wiring Diagram ...................................................................................... 66
Rear Light Harness (W7) Component Location ................................................................................... 67
Rear Light Harness (W7) Wiring Diagram ........................................................................................... 68
Radio Harness (W8) Component Location .......................................................................................... 69
Radio Harness (W8) Wiring Diagram .................................................................................................. 70
Fan Speed Solenoid Harness (W9) Component Location .................................................................... 71
Fan Speed Solenoid Harness (W9) Wiring Diagram ............................................................................ 72
Hydraulic Valve Harness (W10) Component Location ........................................................................ 73
Hydraulic Valve Harness (W10) Wiring Diagram ................................................................................ 74
Attachment Control Frame Harness (W11) Component Location ....................................................... 76
Attachment Control Frame Harness (W11) Wiring Diagram ............................................................... 77
Attachment Control Boom Harness (W12) Component Location ........................................................ 78
Attachment Control Boom Harness (W12) Wiring Diagram ................................................................ 79
Quik-Tatch™ Frame Harness (W13) Component Location .................................................................. 80
Quik-Tatch™ Frame Harness (W13) Wiring Diagram .......................................................................... 81
Quik-Tatch™ Boom Harness (W14) Component Location ................................................................... 82
Quik-Tatch™ Boom Harness (W14) Wiring Diagram ........................................................................... 83
Quik-Tatch™ Actuator Harness (W15) Component Location .............................................................. 83
Quik-Tatch™ Actuator Harness (W15) Wiring Diagram ...................................................................... 84
Heater and Air Conditioner Harness (W16) Component Location ....................................................... 85
Heater and Air Conditioner Harness (W16) Wiring Diagram ............................................................... 86
Fan Bypass Solenoid Harness (W17) Component Location ................................................................. 87
Fan Bypass Solenoid Harness (W17) Wiring Diagram ......................................................................... 88
Group 15 - Sub-System Diagnostics ................................................................................................... 89
Starting Circuit Theory of Operation ................................................................................................... 90
Controller Area Network (CAN) Theory of Operation .......................................................................... 94
Engine Control Unit (ECU) Circuit Theory of Operation ....................................................................... 96
Engagement and Monitor Unit (EMU) Circuit Theory of Operation .................................................... 105
Backup Alarm Circuit Theory of Operation ....................................................................................... 113
Quik-Tatch Circuit Theory of Operation ............................................................................................ 115
Group 16 - Monitor Operation ............................................................................................................ 117
Engagement and Monitor Unit Operation ......................................................................................... 117

Engagement and Monitor Unit Data Items ....................................................................................... 119

Engagement and Monitor Unit Display Messages ............................................................................. 121
Engagement and Monitor Unit Service Menu Operation ................................................................... 122
Engagement and Monitor Unit Initial Configuration .......................................................................... 123
Anti-Theft Security System Operation—If Equipped ......................................................................... 124
Anti-Theft Security System Configuration—If Equipped .................................................................... 126
Anti-Theft Security System Enable—If Equipped .............................................................................. 130
Group 20 - References ......................................................................................................................... 131
Service ADVISOR™ Connection Procedure ....................................................................................... 131
Reading Diagnostic Trouble Codes (DTCs) ....................................................................................... 132
Electrical Component Checks ........................................................................................................... 136
Electrical Component Specifications ................................................................................................. 145
Solenoid Observable Symptom Check .............................................................................................. 148
Alternator Test .................................................................................................................................. 159
Controller Area Network (CAN) Diagnostics ...................................................................................... 161
Auxiliary Hydraulics Calibration ........................................................................................................ 169
Engine Control Unit (ECU) Remove and Install ................................................................................. 171
Engagement and Monitor Unit (EMU) Remove and Install ................................................................ 172
Control Panel Remove and Install ..................................................................................................... 173
Backup Alarm Remove and Install .................................................................................................... 174
Battery Remove and Install .............................................................................................................. 175
Replace (Pull Type) Metri-Pack™ Connectors ................................................................................... 175
Replace (Push Type) Metri-Pack™ Connectors ................................................................................. 175
Replace Metri-Pack™ Connectors ..................................................................................................... 177
Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector ................ 178
Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact ....................... 179
Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular Connectors
................................................................................................................................................... 180
Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Circular Connectors ...................... 182
Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors ................................... 183
Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact ............................................ 184
Replace CINCH™ Connectors ........................................................................................................... 186
Install CINCH™ Contact .................................................................................................................... 188
Repair 32 and 48 Way CINCH™ Connectors ..................................................................................... 190
Remove Connector Body from Blade Terminals ............................................................................... 193

Section 9015 - ELECTRICAL SYSTEM Group 05: System Information
Group 05 - System Information

Electrical Diagram Information
→NOTE:
All System Functional Schematics, Circuit Schematics, and Wiring Diagrams are shown with key switch in
the off position.
System Functional Schematic Diagram
System Functional Schematic Example

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

LEGEND:
1 Component Identification Number
2 Connector
3 Connector End View
4 Wire Harness
5 Wire Number
6 Wire Splice
7 Wire End #1 Termination Location

8 Wire Number
9 Wire Color
10 Wire End #2 Termination Location
Each harness on the machine is drawn showing connectors, wires, and splices. A “W” component identification number
identifies harnesses. (W6, Etc.) The harness is drawn showing spatial arrangement of components and branches.
A component identification or connector number (1) identifies each component. The harness branch (4) is terminated by a top
or side view of the connector (2). If more than one wire is supplied to the connector, a harness side connector end view (3) is
provided. Each wire number is labeled for the appropriate pin. If only one wire is supplied to the connector, the wire number (5)
is indicated.
An “X” component identification number of 100 or higher identifies splices (6). Each splice lists side A wires and side B wires to
differentiate the side of the harness that the wires come from.
A wire legend is provided for each harness. A component identification number is listed in the “END #1” column (7) to indicate
the termination location of one end of a wire. In the center, the wire number (8) and wire color (9) are listed. A component
identification number in the “END #2” column (10) identifies the opposite end of the wire.
Component Location Diagram
The Component Location Diagram is a pictorial view by harness showing location of all electrical components, connectors,
harness main ground locations and harness band and clamp location. Each component will be identified by the same
identification letter/number and description used in the System Functional Schematic Diagram.
Electrical Schematic Symbols
Electrical Schematic Symbols
LEGEND:
1 Battery
2 Wire Splice
3 Fuse
4 Circuit Breaker
5 Fusible Link
6 Power Outlet
7 Alternator
8 Air Conditioner Compressor
9 Compressor
10 Liquid Pump
11 Antenna
12 Diode
13 Zener Diode
14 Capacitor
15 Magnet
16 Flasher
17 Buzzer
18 Horn
19 Alarm
20 Clock
21 Internal Ground
22 Single Point Ground
23 External Ground
24 Sensor
25 Sensor with Normally Open Switch
26 Speed Sensor
27 Rotary Sensor
28 Single Element Bulb
29 Dual Element Bulb
30 Solenoid Operated Hydraulic Valve With Suppression Diode
31 Solenoid Normally Open
32 Solenoid Normally Closed
33 Starter Motor
34 Starter Motor
35 DC Motor
36 DC Stepping Motor
37 Wiper Motor
38 Blower Motor
39 Servo Motor
40 Speedometer
41 Tachometer
42 Temperature Gauge
43 Liquid Level Gauge
44 Gauge
45 Hourmeter
46 Resistor
47 Variable Resistor
48 Manually Adjusted Variable Resistor
49 Multi-Pin Connector
50 Single Pin Connector
51 Connector
52 4 Pin Relay
53 5 Pin Relay
54 5 Pin Relay With Internal Suppression Diode
55 5 Pin Relay With Internal Suppression Resistor
56 Key Switch
57 Temperature Switch Normally Open
58 Temperature Switch Normally Closed
59 Pressure Switch Normally Open
60 Pressure Switch Normally Closed
61 Liquid Level Switch Normally Open
62 Liquid Level Switch Normally Closed
63 Momentary Switch Normally Open
64 Momentary Switch Normally Closed
65 Toggle Switch Normally Open
66 Toggle Switch Normally Closed
Section 9015 - ELECTRICAL SYSTEM Group 10: System Diagrams
67 2 Way Toggle Switch Normally Open

68 2 Way Toggle Switch Normally Closed
69 Manual Switch Operation
70 Push Switch Operation
71 Pull Switch Operation
72 Turn Switch Operation
73 Toggle Switch Operation
74 Pedal Switch Operation
75 Key Switch Operation
76 Detent Switch Operation
77 Temperature Sensor
78 Solar Sensor
79 Pressure Sensor
80 Liquid Level Sensor
Group 10 - System Diagrams

Fuse and Relay Specifications
IMPORTANT:
Install fuse with correct amperage rating to prevent electrical system damage from overload.
Prevent electrical malfunctions from incorrectly installed relays. Install relays with the correct
orientation.
Fuses
The fuses are located behind a panel on the right side of the cab.
Fuse Blocks
LEGEND:
F1 Key Switch Unswitched Power 7.5 A Fuse
F2 Monitor Unswitched Power 10 A Fuse
F3 ECU Unswitched Power 20 A Fuse
F4 Air Seat 10 A Fuse
F5 Dome Light and Accessory Power Socket 10 A Fuse
F6 Lights 20 A Fuse (S.N. —233421)
F6 Lights 25 A Fuse (S.N. 233422— )
F7 Accessory 20 A Fuse
F8 Air Conditioner and Heater 30 A Fuse
F9 Glow Plug 60 A Fuse
F15 Switched Power 10 A Fuse
F16 Horn 10 A Fuse
F17 Handle Switches 5 A Fuse
V1 Remote Start Diode
V2 Polarity Sensing Diode
X61 Fuse Block 1 Connector
X64 Diode Block Connector
X69 Maxi Fuse Block Connector
→NOTE:
The following items are located outside of the fuse and relay center:
F10—Left Flasher Light In-Line 5 A Fuse is located on the back of the cab at the top. See Dual Flasher Harness (W5) Component
Location . (Group 9015-10.)
F11—Right Flasher Light In-Line 5 A Fuse is located on the back of the cab at the top. See Dual Flasher Harness (W5)
F12—Radio In-Line 3 A Fuse is located behind Radio (A7). See Radio Harness (W8) Component Location . (Group 9015-10.)
F13— Quik-Tatch ™ In-Line 30 A Fuse is located near Starter Motor (M1). See Quik-Tatch™ Frame Harness (W13) Component
F19—Beacon In-Line 5 A Fuse (later machines only) is located on the back of the cab at the top. See Dual Flasher Harness (W5)
Relays
Relays are located next to the fuses. To access relays operator station must be raised. See Raising Operator′s Station .
(Operator′s Manual.)
Relay Center
LEGEND:
K1 Starter Relay
K2 Glow Plug Relay
K4 Accessory Relay
K8 Ignition Relay
K13 Quik-Tatch ™ Relay (LOCK)
K14 Quik-Tatch™ Relay (UNLOCK)
W3 Main Harness
→NOTE:
The following items are located outside of the fuse and relay center:
K5—Dual Flasher Relay, see Cab Harness (W2) Component Location . (Group 9015-10.)
K7—Air Conditioner Compressor Clutch Relay, see Heater and Air Conditioner Harness (W16) Component Location . (Group
9015-10.)
K16—Blower Motor (low speed) Relay, see Heater and Air Conditioner Harness (W16) Component Location . (Group 9015-10.)
K17—Blower Motor (medium low speed) Relay, see Heater and Air Conditioner Harness (W16) Component Location . (Group
9015-10.)
K18—Blower Motor (medium high speed) Relay, see Heater and Air Conditioner Harness (W16) Component Location . (Group
9015-10.)
K19—Blower Motor (high speed) Relay, see Heater and Air Conditioner Harness (W16) Component Location . (Group 9015-10.)
Relay Test
Test Connection for Relays A
Test Connection for Relays B
Service Equipment and Tools
SERVICE EQUIPMENT AND TOOLS
JDG1478 Digital Multimeter
IMPORTANT:
orientation.
IMPORTANT: To prevent damage to relay. Do not connect relay directly to battery. Use a fused
power source such as accessory power switch 1-Pin connector (X60) or fused external power supply.
Connect multimeter to terminals 1 and 2. For specifications, see Electrical Component Specifications . (Group 9015-20.)
Connect multimeter to terminals 3 and 4. Multimeter must read open.

Connect 12 V DC (+) to terminal 1, ground (-) terminal 2 then connect multimeter to terminals 3 and 4. Multimeter must
read less than 0.4 Ω.
System Functional Schematic, Wiring Diagram and Component Location

Master Legend
A2—Engagement and Monitor Unit (EMU) ( SE8 )( W2 )
A3—Engine Control Unit (ECU) ( SE5 )( W3 )
A7—Radio ( SE17 )( W8 )
B1—Air Filter Restriction Switch ( SE4 )( W3 )
B2—Hydraulic Oil Temperature Sensor ( SE4 )( W3 )
B3—Hydraulic Oil Filter Restriction Switch ( SE4 )( W3 )
B4—Fuel Level Sensor ( SE8 )( W3 )
B5—Engine Coolant Temperature Sensor ( SE4 )( W1 )
B6—Engine Oil Pressure Switch ( SE4 )( W3 )
B9—Air Conditioner Pressure Switch ( SE20 )( W3 )
B10—Air Conditioner Freeze Control Switch ( SE21 )( W16 )
B15—Auxiliary Proportional Switch ( SE12 )( W6 )
B18—Engine Speed Control Dial ( SE4 )( W2 )
B19—Engine Speed Control Pedal ( SE4 )( W3 )
B21—Fuel Pressure Sensor ( SE4 )( W3 )
B22—Crankshaft Speed Sensor ( SE4 )( W1 )
B23—Camshaft Speed Sensor ( SE4 )( W1 )
B24—Ambient Air Temperature Sensor ( SE4 )( W3 )
B25—Manifold Air Temperature (MAT) Sensor ( SE4 )( W3 )
B26—Left Speaker ( SE17 )( W8 )
B27—Right Speaker ( SE17 )( W8 )
B30—Water-in-Fuel Sensor—If Equipped ( SE19 )( W3 )
B31—Fuel Filter Heater Temperature Switch—If Equipped ( SE19 )( W3 )
E1—Left Front Work Light ( SE16 )( W2 )
E2—Right Front Work Light ( SE16 )( W2 )
E3—Right Tail Light ( SE16 )( W7 )
E4—Left Tail Light ( SE16 )( W7 )
E5—Rear Work Light ( SE16 )( W7 )
E6—Left Flasher Light ( SE18 )( W5 )
E7—Right Flasher Light ( SE18 )( W5 )
E8—Beacon ( SE18 )( W5 )
E9—Dome Light ( SE20 )( W2 )
E10—Water-in-Fuel Indicator—If Equipped ( SE19 )( W3 )
E11—License Plate Light—If Equipped ( SE16 )( W3 )
F1—Key Switch Unswitched Power 7.5 A Fuse ( SE1 )( W3 )
F2—Monitor Unswitched Power 10 A Fuse ( SE7 )( W3 )
F3—ECU Unswitched Power 20 A Fuse ( SE4 )( W3 )
F4—Air Seat 10 A Fuse ( SE18 )( W3 )
F5—Dome Light and Accessory Power Socket 10 A Fuse ( SE19 )( W3 )
F6—Lights 20 A Fuse (S.N. —233421) ( SE16 )( W3 )
F6—Lights 25 A Fuse (S.N. 233422— ) ( SE16 )( W3 )
F7—Accessory 20 A Fuse ( SE16 )( W3 )
F8—Air Conditioner and Heater 30 A Fuse ( SE20 )( W3 )
F9—Glow Plug 60 A Fuse ( SE1 )( W3 )
F10—Left Flasher Light Inline 5 A Fuse ( SE18 )( W5 )
F11—Right Flasher Light Inline 5 A Fuse ( SE18 )( W5 )
F12—Radio Inline 3 A Fuse ( SE17 )( W8 )
F13— Quik-Tatch ™ Inline 30 A Fuse ( SE19 )( W13 )
F15—Switched Power 10 A Fuse ( SE4 )( W3 )
F16—Horn 10 A Fuse ( SE11 )( W3 )
F17—Handle Switches 5 A Fuse ( SE11 )( W3 )
F18—Handle Switches 5 A Fuse ( SE11 )( W3 )
F19—Beacon Inline 5 A Fuse ( SE18 )( W5 )
F20—Fuel Filter Heater 15 A Fuse—If Equipped ( SE19 )( W3 )
G1—Battery ( SE1 )( W3 )
G2—Alternator ( SE2 )( W3 )
G3—12 Volt Auxiliary Power Outlet ( SE19 )( W2 )
H2—Backup Alarm ( SE19 )( W7 )

H3—Horn ( SE11 )( W2 )
H4—Engagement and Monitor Unit Warning Alarm ( SE8 )( W2 )
K1—Starter Relay ( SE1 )( W3 )
K2—Glow Plug Relay ( SE2 )( W3 )
K4—Accessory Relay ( SE16 )( W3 )
K5—Dual Flasher Relay ( SE18 )( W2 )
K7—Air Conditioner Compressor Clutch Relay ( SE21 )( W16 )
K8—Ignition Relay ( SE2 )( W3 )
K10—Fuel Filter Heater Relay— If Equipped ( SE19 )( W3 )
K13—Quik-Tatch™ Relay (LOCK) ( SE19 )( W13 )
K14—Quik-Tatch™ Relay (UNLOCK) ( SE19 )( W13 )
K16—Blower Motor (low speed) Relay ( SE21 )( W16 )
K17—Blower Motor (medium low speed) Relay ( SE21 )( W16 )
K18—Blower Motor (medium high speed) Relay ( SE21 )( W16 )
K19—Blower Motor (high speed) Relay ( SE21 )( W16 )
M1—Starter Motor ( SE1 )( W3 )
M3—Blower Motor ( SE21 )( W16 )
M4—Windshield Wiper Motor ( SE17 )( W2 )
M5—Windshield Washer Motor ( SE17 )( W3 )
M6—Heater Control Valve Actuator ( SE20 )( W3 )
M10—Quik-Tatch™ Motor ( SE19 )( W15 )
M12—Air Seat Compressor ( SE18 )( W2 )
R3—Cab Temperature Control Dial ( SE20 )( W2 )
R4—Blower Resistor ( SE21 )( W16 )
R5—Glow Plugs ( SE2 )( W3 )
R6—CAN Termination Resistor 1 ( SE12 )( W2 )
R7—CAN Termination Resistor 2 ( SE4 )( W3 )
R10—Fuel Filter Heater—If Equipped ( SE19 )( W3 )
S1—Key Switch ( SE1 )( W2 )
S2—Park Brake Switch ( SE7 )( W2 )
S4—Seat Switch ( SE7 )( W2 )
S5—Interlocking Seat Bar Switch ( SE7 )( W2 )
S6—Work Lights Switch ( SE16 )( W2 )
S7—Dual Flasher Switch ( SE18 )( W2 )
S8—High Flow Switch ( SE7 )( W2 )
S9—Blower Speed Dial ( SE20 )( W2 )
S10—Left Reverse Switch ( SE19 )( W4 )
S11—Right Reverse Switch ( SE19 )( W4 )
S12—Windshield Wiper and Washer Switch ( SE17 )( W2 )
S13—Cab Door Switch ( SE7 )( W2 )
S19—Air Conditioner Switch ( SE20 )( W2 )
S21—Auxiliary Hydraulic Override Switch ( SE7 )( W2 )
S24—Dome Light Switch ( SE20 )( W2 )
S25—Two Speed Switch ( SE10 )( W6 )
S26—Quik-Tatch™ Switch ( SE19 )( W2 )
S27—Float Switch ( SE12 )( W6 )
S28—Auxiliary Flow Set Switch ( SE10 )( W6 )
S29—Auxiliary Second Function Switch A ( SE12 )( W6 )
S30—Auxiliary Second Function Switch B ( SE12 )( W6 )
S31—Auxiliary Third Function Switch A ( SE10 )( W6 )
S32—Auxiliary Third Function Switch B ( SE10 )( W6 )
S33—Auxiliary Fourth Function Switch ( SE11 )( W2 )
S34—Horn Switch ( SE10 )( W6 )
S35—Reversing Fan Switch ( SE7 )( W2 )
S36—Creep Mode Switch ( SE7 )( W2 )
S37—Pattern Select Switch ( SE7 )( W2 )
S38—Self Leveling Switch ( SE18 )( W2 )
S39—Air Seat Switch ( SE18 )( W2 )
V1—Remote Start Diode ( SE1 )( W3 )
V2—Polarity Sensing Diode ( SE2 )( W3 )
V5—Alternator Diode ( SE2 )( W3 )

V6—Left Handle Diode ( SE11 )( W11 )
V7—Attachment Control Harness 5-Diode Pack ( SE11 )( W11 )
W1—Engine Harness ( W1 )
W2—Cab Harness ( W2 )
W3—Main Harness ( W3 )
W4—Reverse Switch Harness ( W4 )
W5—Dual Flasher Harness ( W5 )
W6—Control Lever Harness ( W6 )
W7—Rear Light Harness ( W7 )
W8—Radio Harness ( W8 )
W9—Fan Speed Solenoid Harness ( W9 )
W10—Hydraulic Valve Harness ( W10 )
W11—Attachment Control Frame Harness ( W11 )
W12—Attachment Control Boom Harness ( W12 )
W13—Quik-Tatch™ Frame Harness ( W13 )
W14—Quik-Tatch™ Boom Harness ( W14 )
W15—Quik-Tatch™ Actuator Harness ( W15 )
W16—Heater and Air Conditioner Harness ( W16 )
W17—Fan Bypass Solenoid Harness ( W17 )
W19—Antenna ( W8 )
W20—Battery-to-Frame Ground ( SE1 )( W3 )
W21—Starter Ground ( SE1 )( W3 )
W22—Cab Harness Ground ( W2 )( W13 )
X1—Cab Harness-to-Main Harness 14-Pin Connector ( W2 )( W3 )
X2—Cab Harness-to-Main Harness 47-Pin Connector ( W2 )( W3 )
X3—Main Harness-to-Engine Harness 8-Pin Connector ( W1 )( W3 )
X4—Main Harness-to-Hydraulic Valve Harness 6-Pin Connector ( W3 )( W10 )
X8—Main Harness-to-Air Conditioner and Heater Harness 14-Pin Connector ( SE20 )( W3 )
X9—Service Engine Speed Control 3-Pin Connector ( SE4 )( W3 )
X10—Remote Start Box 4-Pin Connector ( SE2 )( W3 )
X11—Injector 6-Pin Connector ( SE5 )( W3 )
X12—Main Harness-to-Dual Flasher Harness 6-Pin Connector ( W3 )( W5 )
X15—Engine Control Unit (ECU) 32-Pin (J1) ( W3 )
X16—Engine Control Unit (ECU) 48-Pin (J2) ( W3 )
X18—Main Harness-to-Reverse Switch Harness ( W3 )( W4 )
X20—Main Harness-to-Battery 1-Pin Connector ( SE1 )( W3 )
X21—Cab Harness-to-Radio Harness 4-Pin Connector ( W2 )( W8 )
X22—Right Control Lever 12-Pin Connector ( SE12 )( W6 )
X24—Left Control Lever 8-Pin Connector ( SE10 )( W6 )
X26—Attachment Control Frame Harness-to-Attachment Control Boom Harness 8-Pin Connector ( W11 )( W12 )
X27—Control Lever Harness-to-Attachment Control Harness 8-Pin Connector ( SE12 )( W6 )( W11 )
X28—Main Harness-to-Control Lever Harness 12-Pin Connector ( W3 )( W6 )
X29—Main Harness-to-Control Lever Harness 4-Pin Connector ( W3 )( W6 )
X30—Main Harness-to-Quik-Tatch™ Harness 4-Pin Connector ( W3 )( W13 )
X32—Quik-Tatch™ 1-Pin Connector ( W13 )( W14 )
X33—Quik-Tatch™ 1-Pin Connector ( W13 )( W14 )
X34—Fan Bypass Solenoid Harness 2-Pin Connector ( W3 )( W17 )
X35—Quik-Tatch™ Boom Harness-to-Quik-Tatch™ Actuator Harness Connector ( W14 )( W15 )
X39—Main Harness-to-Fan Speed Solenoid Harness 2-Pin Connector ( W3 )( W9 )
X40—Service Advisor Connector ( SE9 )( W2 )
X41—Engagement and Monitor Unit (EMU) 16-Pin Connector (J1) ( W2 )
X48—Main Harness-to-Rear Light Harness 6-Pin Connector ( W3 )( W7 )
X49—Attachment Harness Connector A ( W12 )
X50—Attachment Harness Connector B ( W12 )
X60—Accessory Power Switch Connector 1-Pin ( W3 )
X61—Fuse Block 1 Connector ( W3 )
X64—Diode Block Connector ( W3 )

X65—Starter Relay Connector ( W3 )
X66—Glow Plug Relay Connector ( W3 )
X67—Ignition Relay Connector ( W3 )
X68—Accessory Relay Connector ( W3 )
X69—Maxi Fuse Block Connector ( W3 )
X70—Fuel Filter Heater Relay Connector—If Equipped ( W3 )
X99—NOT USED ( W1 )
X100—5414 YEL Splice ( W1 )
X101—P05A RED Splice ( W2 )
X103—M01A PUR Splice ( W2 )
X112—M12A YEL Splice ( W2 )
X113—M13A DK GRN Splice ( W2 )
X114—R13A BLK Splice ( W2 )
X115—M12C YEL Splice ( W2 )
X116—M13C DK GRN Splice ( W2 )
X117—R13C BLK Splice ( W2 )
X121—A05A ORG Splice ( W2 )
X122—G02A2 BLK Splice ( W2 )
X123—L03A1 BRN Splice 1 ( W2 )
X124—L01A1 BRN Splice ( W2 )
X125—G02A1 BLK Splice ( W2 )
X126—P06A1 RED Splice ( W2 )
X127—P10AA RED Splice ( W2 )
X131—R05 BLK Splice ( W3 )
X132—E10 Splice ( W3 )
X133—G01Y1 BLK Splice ( W3 )
X134—R50 BLK Splice ( W3 )
X135—G02 BLK Splice ( W3 )
X137—T03 LT BLU Splice ( W3 )
X138—P10 RED Splice ( W3 )
X141—G01Y2 BLK Splice ( W3 )
X142—A08 ORG Splice ( W3 )
X145—P02 RED Splice 1 ( W3 )
X146—E32 WHT Splice ( W3 )
X148—B01 RED Splice ( W3 )
X149—J07 TAN Splice ( W3 )
X165—G31B BLK Splice ( W3 )
X166—G32B BLK Splice ( W3 )
X168—M12E YEL Splice 2 ( W3 )
X169—M13E DK GRN Splice 2 ( W3 )
X170—R13E BLK Splice 2 ( W3 )
X171—L01 BRN Splice—If Equipped ( W3 )
X200—L05 BRN Splice ( W5 )
X201—L03A1 BRN Splice 2 ( W5 )
X202—G01A BLK Splice 1 ( W5 )
X203—L03A2 BRN Splice ( W5 )
X204—L04 BRN Splice ( W5 )
X207—A04A ORG Splice ( W6 )

X208—P21A RED Splice 2 ( W6 )
X209—P22A RED Splice 2 ( W6 )
X213—P02 RED Splice 2 ( W8 )
X221—H01A GRN Splice ( W10 )
X222—R38A BLK Splice 2 ( W10 )
X223—H34A GRN Splice 2 ( W10 )
X224—H35A GRN Splice 2 ( W10 )
X238—J04A WHT Splice 1 ( W13 )
X240—G01D BLK Splice ( W13 )
X250—RED Splice ( W16 )
X251—BLK Splice ( W16 )
X253—G01 BLK Splice ( W17 )
Y2—Boom Spool Lock Solenoid ( SE9 ) ( W10 )
Y3—Bucket Spool Lock Solenoid ( SE9 ) ( W10 )
Y4—Port Lock Solenoid ( SE9 ) ( W10 )
Y5—Park Brake Solenoid ( SE9 ) ( W3 )
Y6—Two Speed Solenoid ( SE9 )( W3 )
Y7—High Flow Solenoid ( SE9 )( W3 )
Y13—Air Conditioning Compressor Clutch Solenoid ( SE20 )( W3 )
Y23—Auxiliary Port (male) Solenoid ( SE9 )( W10 )
Y24—Auxiliary Port (female) Solenoid ( SE9 )( W10 )
Y25—Fuel Injector 1 ( SE6 )
Y29—Fuel Injector 5 (if equipped) ( SE6 )
Y30—Hydraulic Fan Speed Solenoid ( SE5 )( W3 )( W9 )
Y31—Hydraulic Reversing Fan Solenoid A ( SE6 )( W3 )
Y32—Hydraulic Reversing Fan Solenoid B ( SE5 )( W3 )
Y33—Fan Bypass Solenoid 1 ( SE2 )( W17 )
Y34—Fan Bypass Solenoid 2 ( SE2 )( W17 )
Y38—Self Leveling Solenoid ( SE18 )( W3 )
System Functional Schematic
System Functional Schematic (SE1—SE3)
LEGEND:
G1 Battery
G2 Alternator
K1 Starter Relay
K2 Glow Plug Relay
K8 Ignition Relay
M1 Starter Motor
R5 Glow Plugs
S1 Key Switch
V5 Alternator Diode
W20 Battery-to-Frame Ground
W21 Starter Ground
X1 Cab Harness-to-Main Harness 14-Pin Connector
X10 Remote Start Box 4-Pin Connector
X20 Main Harness-to-Battery 1-Pin Connector
Y33 Fan Bypass Solenoid 1
LEGEND:
A3 Engine Control Unit (ECU)
B2 Hydraulic Oil Temperature Sensor
B3 Hydraulic Oil Filter Restriction Switch
B5 Engine Coolant Temperature Sensor
B6 Engine Oil Pressure Switch
B18 Engine Speed Control Dial
B19 Engine Speed Control Pedal
B21 Fuel Pressure Sensor
B22 Crankshaft Speed Sensor
B23 Camshaft Speed Sensor
B25 Manifold Air Temperature (MAT) Sensor
R7 CAN Termination Resistor 2
X3 Main Harness-to-Engine Harness 8-Pin Connector
X9 Service Engine Speed Control 3-Pin Connector
X11 Injector 6-Pin Connector
X15 Engine Control Unit (ECU) 32-Pin Connector (J1)
Y25 Fuel Injector 1
Y26 Fuel Injector 2
Y27 Fuel Injector 3
Y28 Fuel Injector 4
Y29 Fuel Injector 5 (if equipped)
Y30 Hydraulic Fan Speed Solenoid
Y31 Hydraulic Reversing Fan Solenoid A
Y32 Hydraulic Reversing Fan Solenoid B
LEGEND:
A2 Engagement and Monitor Unit (EMU)
H4 Engagement and Monitor Unit Warning Alarm
S2 Park Brake Switch
S4 Seat Switch
S5 Interlocking Seat Bar Switch
S8 High Flow Switch
S13 Cab Door Switch
S21 Auxiliary Hydraulic Override Switch
S35 Reversing Fan Switch
X4 Main Harness-to-Hydraulic Valve Harness 6-Pin Connector
X40 Service Advisor Connector
X41 Engagement and Monitor Unit (EMU) 16-Pin Connector (J1)
Y2 Boom Spool Lock Solenoid
Y3 Bucket Spool Lock Solenoid
Y4 Port Lock Solenoid
Y5 Park Brake Solenoid
Y6 Two Speed Solenoid
Y7 High Flow Solenoid
Y23 Auxiliary Port (male) Solenoid
Y24 Auxiliary Port (female) Solenoid
→NOTE:
LEGEND:
B15 Auxiliary Proportional Switch
F16 Horn 10 A Fuse
H3 Horn
S25 Two Speed Switch
S28 Auxiliary Flow Set Switch
S29 Auxiliary Second Function Switch A
S30 Auxiliary Second Function Switch B
S31 Auxiliary Third Function Switch A
S32 Auxiliary Third Function Switch B
S33 Auxiliary Fourth Function Switch
S34 Horn Switch
V6 Left Handle Diode
V7 Attachment Control Harness 5-Diode Pack
X22 Right Control Lever 12-Pin Connector
X24 Left Control Lever 8-Pin Connector
X26 Attachment Control Frame Harness-to-Attachment Control Boom Harness 8-Pin Connector
X27 Control Lever Harness-to-Attachment Control Harness 8-Pin Connector
X28 Main Harness-to-Control Lever Harness 12-Pin Connector
X49 Attachment Harness Connector A
X50 Attachment Harness Connector B
LEGEND:
1 Later Machines
A7 Radio
B26 Left Speaker
B27 Right Speaker
E1 Left Front Work Light
E2 Right Front Work Light
E3 Right Tail Light
E4 Left Tail Light
E5 Rear Work Light
E6 Left Flasher Light
E7 Right Flasher Light
E8 Beacon
E11 License Plate Light—If Equipped
F4 Air Seat 10 A Fuse
F6 Lights 20 A Fuse (S.N. —233421)
F6 Lights 25 A Fuse (S.N. 233422— )
F10 Left Flasher Light Inline 5 A Fuse
F11 Right Flasher Light Inline 5 A Fuse
F12 Radio Inline 3 A Fuse
F19 Beacon Inline 5 A Fuse (later machines)
K4 Accessory Relay
K5 Dual Flasher Relay
M4 Windshield Wiper Motor
M5 Windshield Washer Motor
M12 Air Seat Compressor
S6 Work Lights Switch
S7 Dual Flasher Switch
S12 Windshield Wiper and Washer Switch
S38 Self Leveling Switch
S39 Air Seat Switch
Y38 Self Leveling Solenoid
LEGEND:
B9 Air Conditioner Pressure Switch
B10 Air Conditioner Freeze Control Switch
B30 Water-in-Fuel Sensor—If Equipped
B31 Fuel Filter Heater Temperature Switch—If Equipped
E10 Water-in-Fuel Indicator—If Equipped
E9 Dome Light
F5 Dome Light and Accessory Power Socket 10 A Fuse
F8 Air Conditioner and Heater 30 A Fuse
F13 Quik-Tatch Inline 30 A Fuse
F20 Fuel Filter Heater 15 A Fuse—If Equipped
G3 12 Volt Auxiliary Power Outlet
K7 Air Conditioner Compressor Clutch Relay
K10 Fuel Filter Heater Relay— If Equipped
K13 Quik-Tatch Relay (LOCK)
K14 Quik-Tatch Relay (UNLOCK)
K16 Blower Motor (low speed) Relay
K17 Blower Motor (medium low speed) Relay
K18 Blower Motor (medium high speed) Relay
K19 Blower Motor (high speed) Relay
M3 Blower Motor
M6 Heater Control Valve Actuator
M10 Quik-Tatch Motor
R3 Cab Temperature Control Dial
R4 Blower Resistor
R10 Fuel Filter Heater—If Equipped
S9 Blower Speed Dial
S10 Left Reverse Switch
S11 Right Reverse Switch
S19 Air Conditioner Switch
S24 Dome Light Switch
S26 Quik-Tatch Switch
X8 Main Harness-to-Air Conditioner and Heater Harness 14-Pin Connector
Y13 Air Conditioner Compressor Clutch Solenoid
Engine Harness (W1) Component Location
Engine Harness (W1) Component Location

LEGEND:
W1 Engine Harness
X99 NOT USED
Engine Harness (W1) Wiring Diagram
Engine Harness (W1) Wiring Diagram

LEGEND:
X99 NOT USED

X100 5414 YEL Splice
Cab Harness (W2) Component Location
Cab Harness (W2) Component Location

LEGEND:
A2 Engagement and Monitor Unit (EMU) (not shown)
E9 Dome Light
E10 Water-in-Fuel Indicator—If Equipped
H3 Horn
S1 Key Switch
S4 Seat Switch
S8 High Flow Switch
S13 Cab Door Switch
S36 Creep Mode Switch
S37 Pattern Select Switch
S39 Air Seat Switch
W2 Cab Harness
W22 Cab Harness Ground
X21 Cab Harness-to-Radio Harness 4-Pin Connector
Cab Harness (W2) Wiring Diagram
Cab Harness (W2) Wiring Diagram (1 of 2)
LEGEND:
S4 Seat Switch
S39 Air Seat Switch
W22 Cab Harness Ground
X101 P05A RED Splice
X103 M01A PUR Splice
Cab Harness (W2) Wiring Diagram (2 of 2)
LEGEND:
E9 Dome Light
H3 Horn
S1 Key Switch
S8 High Flow Switch
S13 Cab Door Switch
S36 Creep Mode Switch
S37 Pattern Select Switch
W2 Cab Harness
X112 M12A YEL Splice
X113 M13A DK GRN Splice
X114 R13A BLK Splice
X115 M12C YEL Splice
X116 M13C DK GRN Splice
X117 R13C BLK Splice
X121 A05A ORG Splice
X122 G02A2 BLK Splice
X123 L03A1 BRN Splice 1
X124 L01A1 BRN Splice
X125 G02A1 BLK Splice
X126 P06A1 RED Splice
X127 P10AA RED Splice
Main Harness (W3) Component Location
Main Harness (W3) Component Location (1 of 2)

LEGEND:

B30 Water-in-Fuel Sensor—If Equipped
B31 Fuel Filter Heater Temperature Switch—If Equipped
E11 License Plate Light—If Equipped
R5 Glow Plugs
R10 Fuel Filter Heater—If Equipped
W3 Main Harness
W17 Fan Bypass Solenoid Harness—If Equipped
X12 Main Harness-to-Duel Flasher Harness 6-Pin Connector
X15 Engine Control Unit (ECU) 32-Pin (J1)
X18 Main Harness-to-Reverse Switch Harness
X30 Main Harness-to-Quik-Tatch Harness 4-Pin Connector
X34 Fan Bypass Solenoid Harness 2-Pin Connector
X48 Main Harness-to-Rear Light Harness 6-Pin Connector
X60 Accessory Power Switch Connector 1-Pin
X65 Starter Relay Connector
X66 Glow Plug Relay Connector
X67 Ignition Relay Connector
X68 Accessory Relay Connector
X70 Fuel Filter Heater Relay Connector—If Equipped
Y13 Air Conditioning Compressor Clutch Solenoid
Y33 Fan Bypass Solenoid 1—If Equipped
Y34 Fan Bypass Solenoid 2—If Equipped
Main Harness (W3) Component Location (2 of 2)

LEGEND:

G1 Battery
G2 Alternator
M1 Starter Motor
V5 Alternator Diode
W3 Main Harness
W21 Starter Ground
Main Harness (W3) Wiring Diagram
Main Harness (W3) Wiring Diagram (S.N. —195912) (1 of 2)
LEGEND:
G2 Alternator
M1 Starter Motor
R5 Glow Plugs
V5 Alternator Diode
W21 Starter Ground
X39 Main Harness-to-Fan Speed Solenoid Harness 2-Pin Connector
X131 R05 BLK Splice
X132 E10 Splice
X133 G01Y1 BLK Splice
X134 R50 BLK Splice
X135 G02 BLK Splice
X165 G31B BLK Splice
Main Harness (W3) Wiring Diagram (S.N. —195912) (2 of 2)
LEGEND:
K1 Starter Relay
K2 Glow Plug Relay
K4 Accessory Relay
K8 Ignition Relay
X12 Main Harness-to-Dual Flasher Harness 6-Pin Connector
X137 T03 LT BLU Splice
X138 P10 RED Splice
X139 P09 RED Splice
X140 P06 RED Splice
X142 A08 ORG Splice
X143 P40 RED Splice
X144 P04 RED Splice
X145 P02 RED Splice 1
X146 E32 WHT Splice
X147 E01 WHT Splice
X148 B01 RED Splice
X149 J07 TAN Splice
X150 B07 RED Splice
X151 B10 RED Splice
X163 E03 WHT Splice
X167 P21 RED Splice
X168 M12E YEL Splice 2
X169 M13E DK GRN Splice 2
X170 R13E BLK Splice 2
Main Harness (W3) Wiring Diagram—With Heater and Air Conditioning (S.N. 195913— ) (1 of 2)
LEGEND:
G2 Alternator
M1 Starter Motor
R5 Glow Plugs
V5 Alternator Diode
W21 Starter Ground
X131 R05 BLK Splice
X132 E10 Splice
X134 R50 BLK Splice
X135 G02 BLK Splice
Main Harness (W3) Wiring Diagram—With Heater and Air Conditioning (S.N. 195913— ) (2 of 2)
LEGEND:
K1 Starter Relay
K2 Glow Plug Relay
K4 Accessory Relay
K8 Ignition Relay
X138 P10 RED Splice
X139 P09 RED Splice
X140 P06 RED Splice
X142 A08 ORG Splice
X143 P40 RED Splice
X144 P04 RED Splice
X146 E32 WHT Splice
X147 E01 WHT Splice
X148 B01 RED Splice
X149 J07 TAN Splice
X150 B07 RED Splice
X151 B10 RED Splice
X163 E03 WHT Splice
X167 P21 RED Splice
Main Harness (W3) Wiring Diagram—Without Heater and Air Conditioning (S.N. 195913— ) (1 of 2)
LEGEND:
G2 Alternator
M1 Starter Motor
R5 Glow Plugs
V5 Alternator Diode
W21 Starter Ground
X131 R05 BLK Splice
X132 E10 Splice
X134 R50 BLK Splice
X135 G02 BLK Splice
Main Harness (W3) Wiring Diagram—Without Heater and Air Conditioning (S.N. 195913— ) (2 of 2)
LEGEND:
K1 Starter Relay
K2 Glow Plug Relay
K4 Accessory Relay
K8 Ignition Relay
X138 P10 RED Splice
X140 P06 RED Splice
X143 P40 RED Splice
X144 P04 RED Splice
X146 E32 WHT Splice
X147 E01 WHT Splice
X148 B01 RED Splice
X149 J07 TAN Splice
X150 B07 RED Splice
X151 B10 RED Splice
X163 E03 WHT Splice
X167 P21 RED Splice
Reverse Switch Harness (W4) Component Location
Reverse Switch Harness (W4) Component Location

LEGEND:
W3 Main Harness
W4 Reverse Switch Harness
X18 Main Harness-to-Reverse Switch Harness 4-Pin Connector
Reverse Switch Harness (W4) Wiring Diagram
Reverse Switch Harness (W4) Wiring Diagram

LEGEND:
Dual Flasher Harness (W5) Component Location
Dual Flasher Harness (W5) Component Location (early machines)

LEGEND:
E3 Right Tail Light
E4 Left Tail Light
E5 Rear Work Light
E8 Beacon
F10 Left Flasher Light In-Line 5 A Fuse
F11 Right Flasher Light In-Line 5 A Fuse
H2 Backup Alarm
W3 Main Harness
W5 Dual Flasher Harness
W7 Rear Light Harness
Dual Flasher Harness (W5) Component Location (later machines)

LEGEND:
E3 Right Tail Light
E4 Left Tail Light
E5 Rear Work Light
E8 Beacon
F19 Beacon In-Line 5 A Fuse
H2 Backup Alarm
W3 Main Harness
W5 Dual Flasher Harness
W7 Rear Light Harness
Dual Flasher Harness (W5) Wiring Diagram
Dual Flasher Harness (W5) Wiring Diagram (early machines)

LEGEND:
E8 Beacon

X200 L05 BRN Splice
X202 G01A BLK Splice 1
X204 L04 BRN Splice
Dual Flasher Harness (W5) Wiring Diagram (later machines)
LEGEND:
E8 Beacon
F19 Beacon In-Line 5 A Fuse
X200 L05 BRN Splice
X204 L04 BRN Splice
Control Lever Harness (W6) Component Location
Control Lever Harness (W6) Component Location

LEGEND:
W3 Main Harness
W6 Control Lever Harness
X22 Right Joystick 12-Pin Connector (S28, S29, S30)
X24 Left Joystick 8-Pin Connector (S25, S31, S32, S34)
Control Lever Harness (W6) Wiring Diagram
Control Lever Harness (W6) Wiring Diagram
LEGEND:
X22 Right Joystick 12-Pin Connector (S28, S29, S30)
X24 Left Joystick 8-Pin Connector (S25, S31, S32, S34)
X207 A04A ORG Splice
X208 P21A RED Splice 2
X209 P22A RED Splice 2
Rear Light Harness (W7) Component Location
See Dual Flasher Harness (W5) Component Location . (Group 9015-10.)
Rear Light Harness (W7) Wiring Diagram
Rear Light Harness (W7) Wiring Diagram

LEGEND:
E3 Right Tail Light
E4 Left Tail Light
E5 Rear Work Light
H2 Backup Alarm
Radio Harness (W8) Component Location
Radio Harness (W8) Component Location

LEGEND:
A7 Radio
B26 Left Speaker
B27 Right Speaker
F12 Radio In-Line 3 A Fuse
W8 Radio Harness
W19 Antenna
Radio Harness (W8) Wiring Diagram
Radio Harness (W8) Wiring Diagram

LEGEND:
A7 Radio
B26 Left Speaker
B27 Right Speaker
F12 Radio In-Line 3 A Fuse
X213 P02 RED Splice
X214 P16 RED Splice
Fan Speed Solenoid Harness (W9) Component Location
Fan Speed Solenoid Harness (W9) Component Location

LEGEND:
W3 Main Harness
W9 Fan Speed Solenoid Harness
Fan Speed Solenoid Harness (W9) Wiring Diagram
Fan Speed Solenoid Harness (W9) Wiring Diagram

LEGEND:
Hydraulic Valve Harness (W10) Component Location
Hydraulic Valve Harness (W10) Component Location

LEGEND:
W10 Hydraulic Valve Harness
→NOTE:
Hydraulic Valve Harness (W10) Wiring Diagram
Hydraulic Valve Harness (W10) Wiring Diagram
LEGEND:
X221 H01A GRN Splice
X222 R38A BLK Splice 2
X223 H34A GRN Splice 2
X224 H35A GRN Splice 2
→NOTE:
Attachment Control Frame Harness (W11) Component Location
Attachment Control Frame Harness (W11) Component Location

LEGEND:
W11 Attachment Control Frame Harness
W12 Attachment Control Boom Harness
X27 Main Harness-to-Attachment Control Harness 8-Pin Connector
Attachment Control Frame Harness (W11) Wiring Diagram
Attachment Control Frame Harness (W11) Wiring Diagram

LEGEND:
X226 H15A DKGRN Splice

X230 H11A DKGRN Splice 1
Attachment Control Boom Harness (W12) Component Location
See Attachment Control Frame Harness (W11) Component Location . (Group 9015-10.)
Attachment Control Boom Harness (W12) Wiring Diagram
Attachment Control Boom Harness (W12) Wiring Diagram

LEGEND:
Quik-Tatch™ Frame Harness (W13) Component Location
Quik-Tatch Frame Harness (W13) Component Location

LEGEND:
F13 Quik-Tatch™ In-Line 30 A Fuse
K13 Quik-Tatch™ Relay (LOCK)
M1 Starter Motor
M10 Quik-Tatch ™ Motor
W13 Quik-Tatch™ Frame Harness
W14 Quik-Tatch™ Boom Harness
W15 Quik-Tatch™ Actuator Harness
W21 Starter Ground
X32 Quik-Tatch™h 1-Pin Connector
X33 Quik-Tatch™ 1-Pin Connector
X35 Quik-Tatch™ Boom Harness-to-Quik-Tatch™ Actuator Harness Connector
Quik-Tatch™ Frame Harness (W13) Wiring Diagram
Quik-Tatch Frame Harness (W13) Wiring Diagram

LEGEND:
F13 Quik-Tatch ™ In-Line 30 A Fuse
K13 Quik-Tatch™ Relay (LOCK)
M1 Starter Motor
W21 Starter Ground

X30 Main Harness-to-Quik-Tatch™ Harness 4-Pin Connector
X238 J04A WHT Splice 1
X240 G01D BLK Splice
Quik-Tatch™ Boom Harness (W14) Component Location
See Quik-Tatch™ Frame Harness (W13) Component Location . (Group 9015-10.)
Quik-Tatch™ Boom Harness (W14) Wiring Diagram
Quik-Tatch Boom Harness (W14) Wiring Diagram

LEGEND:
X32 Quik-Tatch ™ 1-Pin Connector
Quik-Tatch™ Actuator Harness (W15) Component Location
See Quik-Tatch™ Frame Harness (W13) Component Location . (Group 9015-10.)
Quik-Tatch™ Actuator Harness (W15) Wiring Diagram
Quik-Tatch Actuator Harness (W15) Wiring Diagram

LEGEND:
M10 Quik-Tatch ™ Motor
Heater and Air Conditioner Harness (W16) Component Location
Heater and Air Conditioner Harness (W16) Component Location

LEGEND:
B10 Air Conditioner Freeze Control Switch—If Equipped
K7 Air Conditioner Compressor Clutch Relay—If Equipped
M3 Blower Motor
R4 Blower Resistor
W16 Heater and Air Conditioner Harness
Heater and Air Conditioner Harness (W16) Wiring Diagram
Heater and Air Conditioner Harness (W16) Wiring Diagram
LEGEND:
B10 Air Conditioner Freeze Control Switch—If Equipped
K7 Air Conditioner Compressor Clutch Relay—If Equipped
M3 Blower Motor
R4 Blower Resistor
X250 RED Splice
X251 BLK Splice
Fan Bypass Solenoid Harness (W17) Component Location
See Main Harness (W3) Component Location . (Group 9015-10.)
Section 9015 - ELECTRICAL SYSTEM Group 15: Sub-System Diagnostics
Fan Bypass Solenoid Harness (W17) Wiring Diagram
Fan Bypass Solenoid Harness Wiring Diagram

LEGEND:
X252 E03 WHT Splice
X253 G01 BLK Splice
Group 15 - Sub-System Diagnostics
Starting Circuit Theory of Operation
Start and Charge Circuits Schematic
LEGEND:
G1 Battery
G2 Alternator
K1 Starter Relay
K2 Glow Plug Relay
K4 Accessory Relay
K8 Ignition Relay
M1 Starter Motor
R5 Glow Plugs
S1 Key Switch
V5 Alternator Diode
W21 Starter Ground
Unswitched power is supplied to the following components:
Starter Motor (M1)

Alternator (G2)
Start Relay (K1)
Glow Plug Relay (K2)
Accessory Relay (K4)
Ignition Relay (K8)
Key Switch (S1)
Engagement and Monitor Unit (EMU) (A2)
Engine Control Unit (ECU) (A3)
→NOTE:
Direct battery power is supplied to key switch unswitched power 7.5 A fuse (F1) and terminal 30 of both
the starter relay (K1) and accessory relay (K4).
The ECU has battery power supplied from (F3) ECU unswitched power 20 A Fuse from X20 main harness-
to-battery 1-pin connector.
RUN Circuit— When key switch (S1) is turned to the RUN position, current flows from terminal I of key switch (S1) to terminal
86 of both the starter relay (K1), and the ignition relay (K8). As a result of terminal 85 of ignition relay (K8) always being
grounded, ignition relay (K8) is energized internally connecting terminals 30 and 87, providing power to switched power 10 A
fuse (F15). Power from fuse (F15) is supplied to terminals 5 and 2 of the park brake switch (S2), and terminal B2 of the engine
control unit (ECU) connector (X16) as a wake-up signal. When the parking brake switch (S2) is engaged, power from terminal 5
is internally connected to terminal 6 and current flows to terminal S1 of key switch (S1).
Remote start diode (V1) is incorporated into the circuit to keep switched battery power from the remote start box 4-pin
connector (X10).
→NOTE:
All RUN circuits remain active in the START position.
START Circuit— The ECU provides the start interlock logic, which uses an internal timer to prevent overheating the starter
motor. The timer allows the starter motor to operate for 120 seconds, after which the starter motor must be inactive for 120
seconds before another start attempt can be made.
The park brake switch (S2) must be engaged for power to continue through park brake switch (S2) terminal 6 to the key switch
(S1) terminal S1.
When key switch (S1) is turned to the START position, current flows through the key switch (S1) from terminal S1 to terminal
S2, then to the ECU terminal B3 of connector (X16). When the ECU receives the start signal at terminal B3, the ECU checks the
status of the internal timer and the engine speed status represented by the signal from crankshaft position sensor (B22). It also
checks for any relevant diagnostic trouble codes DTCs that may be active. If the internal timer is not active, engine speed is
zero, and no relevant DTCs are active, the ECU provides ground at terminal C2 of ECU connector (X16) for terminal 85 of the
starter relay (K1), energizing the relay.
With the starter relay (K1) energized, unswitched battery current flows to the starter motor solenoid, activating starter motor
(M1). At the same time, the ECU activates the internal timer. If the key switch is held in the START position for more than 120
seconds, the ECU will interrupt current flow to the coil of the start relay, which automatically stops cranking of the engine.
As the starter motor cranks the engine, the crankshaft speed sensor (B22) provides a signal representing engine speed to
terminals B4 and D4 of ECU connector (X15). When the ECU detects this signal, it knows the crankshaft is turning. The ECU
allows current to flow to the electronic fuel injectors to start the fuel injection process and, thus, start the engine. For more
information on the ECU and electronic fuel injectors, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group
9015-15.)
When the ECU detects engine speed is equal to or greater than 300 rpm, it will interrupt current flow to the coil of the start
relay, automatically stopping cranking of the engine. This will happen even if the key switch is still held in the START position.
For machines with the anti-theft security system, if the anti-theft system is enabled and locked, the engine will start but will
stop after running 5 seconds. For operation of the anti-theft security system, see Anti-Theft Security System Operation .
If the 120 second timer times out during the cranking process, the ECU transmits a message across the controller area network
(CAN) data line to the engagement and monitor unit (EMU) requesting the WAIT TO START message to appear on the display. A
DTC is also generated by the ECU to indicate the starter motor must remain inactive to avoid damage; this DTC is not stored
but shown only when active.
If the key switch is turned to the START position before the starter motor has been inactive for 120 seconds, the ECU prevents
current from flowing to the coil of the start relay. The starter cannot be activated until the required 120 seconds have elapsed.
→NOTE:
For EMU power-up and operation, see Engagement and Monitor Unit (EMU) Circuit Theory of Operation .
(Group 9015-15.)
Cold Start Aid— Glow plugs with optional fan bypass solenoids 1 and 2 (Y33 and Y34) are used.
The engine control unit (EMU) provides power from terminal H4 to terminal 86 of the glow plug relay (K2), energizing the relay.
If equipped, optional fan bypass solenoids 1 and 2 (Y33 and Y34) will also be energized. With the glow plug relay energized,
power flows from the battery, through the glow plug fuse (F9) and glow plug relay (K2) to the glow plugs. Glow plugs will be
activated for up to 30 seconds or until engine speed is greater than 800—1000 rpm. After the engine reaches 800 rpm or
greater, the ECU will keep the glow plugs energized for an additional 10 seconds. When the glow plug relay is energized, the
WAIT TO START indicator will illuminate on the EMU display. Glow plug activation is determined by taking the coldest
temperature from one of the following: ambient air temperature sensor (B24), engine coolant temperature sensor (B5),
hydraulic oil temperature sensor (B2), or internal ECU temperature.
Charge Circuit— Unswitched battery voltage is available at the B+ terminal of the alternator (G2) at all times.
When the key switch (S1) is turned to the START or RUN position, current flows to the coil of accessory relay (K4), energizing
the relay. With the accessory relay energized, current flows through the accessory 20 A fuse (F7) to the D+ terminal of the
alternator (G2), energizing (exciting) the rotor field windings. The energized winding cause the alternator to generate power for
the electrical system and charging the battery. The circuit is protected by fuse (F7) and the alternator diode (V5).
The engagement and monitor unit (EMU) monitors system voltage at terminal H of EMU connector (X42). If the EMU detects
voltage to be less than 11.7 V or greater than 16.2 V, the battery light on the EMU will come on. For information on battery
voltage monitoring, see Engagement and Monitor Unit (EMU) Circuit Theory of Operation . (Group 9015-15.)
Remote Start— The polarity sensing diode (V2) is incorporated into the circuit to keep switched battery power from the key
switch (S1) when using a remote start box. With the remote start box connected power can flow to the park brake solenoid
(Y5), to engage and disengage the park brake with cab raised and in the locked position. The engagement and monitor unit
(EMU) processes the information that a remote start box is being used to determine whether or not to enable the hydraulics
and hydrostatics. For more information, see Engagement and Monitor Unit (EMU) Circuit Theory of Operation . (Group 9015-15.)
Controller Area Network (CAN) Theory of Operation
Controller Area Network Circuit Schematic
LEGEND:
W2 Cab Harness
W3 Main Harness
W21 Starter Ground
Controller Area Network (CAN) Overview— The controller area network (CAN) provides a standardized means for
electronic controllers and other devices to communicate with each other.
The CAN consists of two wires: CAN high and CAN low. These two wires carry signals opposite to each other to overcome noise
interference and minimize communication errors. The high and low wires, along with a ground wire, are woven together
forming what is called a twisted triple. The twisted triple provides an additional method of reducing interference and thus helps
the devices communicate with minimal errors.
The 120 ohm termination resistors, located at opposite ends of the CAN bus, also help prevent signal errors.
The CAN is an arbitration based system. This means that a low priority message always allows a high priority message to go
first. Each CAN device checks to see if the bus is idle before it transmits a signal. Whichever device gets on the bus first is able
to transmit its signal.
When two or more devices are transmitting at the same time, the device with the highest priority has access to the bus. The
device that loses arbitration immediately retransmits its signal when the device with the higher priority has completed its
transmission.
Each controller has the ability to generate a diagnostic trouble code (DTC) if CAN communication is lost. Refer to DTC
diagnostics of specific controller in Section 9001. For general CAN diagnostics, see Controller Area Network (CAN) Circuit Test .
(Group 9015-20.)
CAN— provides the communication link for the following devices:
A2—Engagement and Monitor Unit (EMU)

A3—Engine Control Unit (ECU)
Operations and functions of the individual devices on CAN are covered separately.
For the EMU, see Engagement and Monitor Unit (EMU) Circuit Theory of Operation . (Group 9015-15.)
For the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.)
CAN also includes the following components:
CAN Termination Resistor 1 (R6)

CAN Termination Resistor 2 (R7)
Service ADVISOR ™ Diagnostic Connector (X40)
The Service ADVISOR diagnostic connector provides an interface for connecting diagnostic equipment such as a laptop. See
Service ADVISOR™ Connection Procedure . (Group 9015-20.)
Engine Control Unit (ECU) Circuit Theory of Operation
Engine Control Unit Circuit Schematic (1 of 2)
LEGEND:
A4 Hydraulic Control Unit (HCU)
G1 Battery
K1 Starter Relay
K2 Glow Plug Relay
K8 Ignition Relay
M1 Starter Motor
R5 Glow Plugs
S1 Key Switch
W21 Starter Ground
X45 Hydraulic Control Unit (HCU) 48-Pin Connector (J2)
Engine Control Unit Circuit Schematic (2 of 2)
LEGEND:
Y25 Fuel Injector 1
Y26 Fuel Injector 2
Y27 Fuel Injector 3
Y28 Fuel Injector 4
Y29 Fuel Injector 5 (if equipped)
Engine Control Unit (ECU) (A1)— For component location, see Main Harness (W3) Component Location . (Group 9015-10.)
The ECU uses information received from various sensors to determine the correct amount of fuel and injection timing based on
load, temperatures, and operator input. Some of the data calculated by the ECU is transmitted across the controller area
network (CAN) data line to the engagement and monitor unit (EMU) (A2), and the hydraulic control unit (HCU) (A4) if equipped.
For more information on the EMU, see Engagement and Monitor Unit (EMU) Circuit Theory of Operation . (Group 9015-15.)
For more information on the CAN, see Controller Area Network (CAN) Theory of Operation . (Group 9015-15.)
For more information on the HCU—if equipped, see Electrohydraulic (EH) Controls Circuit Theory of Operation . (Group
9015-15.)
The ECU also detects malfunctions in the sensors and sensor circuits, or abnormal operating conditions. When this happens,
the ECU will generate a diagnostic trouble code (DTC). See Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group
9001-10.)
For sensor specifications, see Electrical Component Checks . (Group 9015-20.)
Whenever an engine DTC occurs, the information is captured or recorded. The information generated is called a Snapshot. The
Snapshot information is categorized in two types: Snapshot Capture and Snapshot Recording. For more information, see
Snapshot Instructions . (CTM101019.)
The ECU contains a barometric air pressure (BAP) sensor that is located inside the ECU. This sensor is used to determine the
pressure of the ambient air at the mounting location of the ECU. The BAP sensor helps the ECU determine the air density for
calculating the correct air/fuel ratio. This sensor cannot be repaired or replaced without replacing the entire ECU.
The ECU also contains a temperature sensor that is located inside the ECU. This sensor is used to determine the internal
temperature of the ECU. If the ECU temperature exceeds specification, the ECU will limit the speed of the engine in an attempt
to protect the ECU from permanent damage. This sensor cannot be repaired or replaced without replacing the entire ECU.
Engine Protection— Engine protection is provided by the ECU for the sensors listed below.
B5—Engine Coolant Temperature Sensor

B6—Engine Oil Pressure Switch
B21—Fuel Pressure Sensor
B22—Crankshaft Speed Sensor
B25—Manifold Air Temperature (MAT) Sensor
The ECU will decrease the amount of fuel that is delivered to the engine (fuel derate), set the engine to a certain speed (speed
derate), or shut the engine down when sensor inputs exceed normal operating ranges. Immediate recovery of derates is
possible by throttling back or reducing load to the point of limiting the engine load. A diagnostic trouble code (DTC) always
accompanies a derate. For information on PowerTech E ™ engine deration, see PowerTech™ E 2.4L and 3.0L Diesel Engines .
(CTM101019.)
ECU Power-Up and Ground— The ECU receives unswitched battery power from ECU unswitched power 20-amp fuse (F3) at
terminals L1, L4, M1, and M4 of ECU connector (X16). The ECU ground is provided at terminals L2, L3, and M2 of ECU connector
(X16).
When the key switch is turned to the ON or START position, the ECU receives switched power at terminal B2 of ECU connector
(X16). On manual control machines (S.N. —195912) and EH control machines (S.N. —196102), switched power comes from
ignition relay (K8) and switched power 10 A fuse (F15). On manual control machines (S.N. 195913— ) and EH control machines
(S.N. 196103— ), switched power to ECU is supplied from terminal I on the key switch.
Engine Speed Control— The engine speed control consists of the engine speed control dial (B18) and the engine speed
control pedal (B19).
The ECU supplies a 5-volt reference voltage to the engine speed control dial (B18) at terminal D3 and the engine speed control
pedal (B19) at terminal F3 of ECU connector (X15). The ECU provides ground to the engine speed control dial (B18) at terminal
E2 and the engine speed control pedal (B19) at terminal D2 of ECU connector (X15).
The ECU receives an analog signal from these sensors as follows:
Engine Speed Control Dial (B18): The engine speed control dial is a potentiometer type sensor that sends an analog signal
representing the desired engine speed (control knob position) to terminal A4 of ECU connector (X16). The ECU compares the
analog signal with values recorded during self-calibration and then responds by increasing or decreasing engine speed
accordingly.
The ECU will default engine speed to slow idle on engine startup regardless of engine speed control dial position. The operator
must move the engine speed control dial to slow idle position and then increase the setting to the desired speed to get the
engine speed to increase.
The engine speed control dial input has a normal operating range from 15% (approximately 0.75 volts) at zero throttle to 86%
(approximately 4.3 volts) at full throttle. The ECU will start self-calibration at 30% (approximately 1.5 volts) for zero throttle and
70% (approximately 3.5 volts) for full throttle. The input will be considered to be out-of-range if the signal is below 5%
(approximately 0.25 volts) or above 95% (approximately 4.75 volts), at which point a DTC will be generated.
Engine Speed Control Pedal (B19): The engine speed control pedal (B19) is a Hall effect type sensor that sends an analog signal
representing the pedal position to terminal F3 of ECU connector (X16). This signal represents desired engine speed, which the
ECU compares with values recorded during self-calibration. The ECU detects this signal and responds by increasing or
decreasing engine speed accordingly.
The foot throttle sensor input has a normal operating range from 12% (approximately 0.6 volts) at zero throttle to 88%
(approximately 4.4 volts) at full throttle. The ECU will start self-calibration at 20% (approximately 1 volt) for zero throttle and
60% (approximately 3 volts) for full throttle. The input will be considered to be out-of-range if the signal is below 5%
(approximately 0.25 volts) or above 95% (approximately 4.75 volts), at which point a DTC will be generated.
The ECU transmits the engine speed control dial position and engine speed control pedal position information across the CAN
data line to the engagement and monitor unit (EMU) (A2), where both can be displayed as a live value in the MAIN MENU /
DIAGNOSTIC / ENGINE submenu.
Fuel Pressure Sensor (B21)— The ECU supplies a 5-volt reference voltage to the fuel pressure sensor at terminal G2 of ECU
connector (X16). The ECU provides ground to the fuel pressure sensor at terminal G3 of ECU connector (X16).
The fuel pressure sensor sends an analog signal representing fuel pressure to terminal B3 of ECU connector (X16). The ECU
uses this signal to monitor the high pressure side of the fuel system and apply derate conditions as follows:
If the ECU senses a value that is out of valid range, the ECU will derate the engine to 50% of full power.
Engine returns to full power when the fuel pressure is in range.
The ECU transmits the fuel pressure information across the CAN data line to the engagement and monitor unit (EMU), where it
can be displayed as a live value in the MAIN MENU / DIAGNOSTIC / ENGINE submenu.
IMPORTANT:
Shutting down an overheated engine too quickly may produce hot spots that could damage the engine.
Always allow the engine coolant temperature to normalize as much as possible by first reducing the
engine load, then running the engine at slow idle for several minutes.
IMPORTANT:
When the red STOP light flashes and the monitor alarm is activated, the machine, and in some cases the
engine, must be stopped immediately or serious damage could result.
Engine Coolant Temperature Sensor (B5)— The ECU senses resistance from the engine coolant temperature sensor at
terminals C3 of ECU connector (X15). The ECU uses this signal to monitor the coolant temperature and apply derate conditions
as follows:
If the coolant temperature reaches 111°C (232°F), the ECU will derate the engine 5% per minute to 80% of full power.
If the coolant temperature reaches 113°C (236°F), the ECU will derate the engine 20% per minute to 40% of full power.
Engine returns to full power (at a rate of 5% per minute) when the engine coolant temperature drops below the derate
threshold temperature.
If the ECU senses a value that is out of valid range, the ECU will use the default temperature of 90°C (194°F).
The ECU transmits the engine coolant temperature information across the CAN data line to the engagement and monitor unit
(EMU). The EMU uses this information to determine the position of the pointer on the engine coolant temperature gauge.
When the engine coolant temperature becomes more than 113°C (235°F), the following will occur:
The pop-up message ENGINE TEMP HIGH will appear on the display.
The engine coolant temperature warning light and the red STOP light will flash in unison.
The monitor alarm will beep every 0.5 seconds until acknowledged.
A DTC is displayed and stored in memory.
For more information on the monitor warning lights and gauges, See Gauges and Indicator Lights . (Operator′s Manual.)
The status of the engine coolant temperature sensor can be displayed as a live value in the MAIN MENU / DIAGNOSTIC / ENGINE
submenu.
Manifold Air Temperature (MAT) Sensor (B25)— The ECU senses resistance from the MAT sensor at terminals C2 and C3
of ECU connector (X15). The ECU uses this signal to monitor the manifold air temperature and apply derate conditions as
follows:
If the ECU senses a manifold air temperature above 89°C (192°F), the ECU will derate the engine 5% per minute up to
80% of full power.
If the ECU senses a manifold air temperature above 91°C (196°F), the ECU will derate the engine 20% per minute up to
40% of full power.
Engine returns to full power (at the rate of 5% per minute) when the manifold air temperature falls below the derate
temperature.
The ECU transmits the MAT information across the CAN data line to the engagement and monitor unit (EMU), where it can be
displayed as a live value in the MAIN MENU / DIAGNOSTIC / ENGINE submenu.
If the manifold air temperature rises above 91°C (196°F), the following will occur:
The red STOP light will flash.

The monitor alarm will beep every 0.5 seconds until acknowledged.
A DTC is displayed and stored in memory.
Crankshaft Speed Sensor (B22)— The crankshaft speed sensor is an inductive-type pickup sensor that detects teeth on the
crankshaft timing gear. The crankshaft timing gear is composed of 45 evenly-spaced teeth. There is a 3-tooth section with no
notches. The 3-tooth section helps the ECU determine when cylinder #1 is at top-dead-center (TDC).
The ECU detects the signal from the crankshaft speed sensor at terminals B4 and D4 of ECU connector (X15).
The ECU uses the crankshaft speed input to determine the angular position of the crankshaft in its 360° field of rotation and
engine (crankshaft) speed. The ECU sends the engine speed information across the CAN data line to the EMU, where it appears
on the run-time screen as engine rpm.
Based on information from the crankshaft and camshaft speed sensors, the ECU calculates the correct start of injection and
amount of fuel to inject, then commands the electronic injectors accordingly. If there is a problem with the crankshaft speed
sensor, the ECU will use the camshaft speed sensor to determine engine timing. This may require prolonged engine cranking to
start the engine.
If the ECU detects an invalid signal (“noisy,” invalid pattern, or missing pulse) from the crankshaft speed sensor, the ECU will
derate the engine 20% per minute up to 50% of full power. The engine will return to full power (at the rate of 20% per minute)
when the ECU detects a valid crankshaft speed sensor signal.
Camshaft Speed Sensor (B23)— Camshaft (pump) speed sensor is an inductive-type pickup sensor that detects teeth on the
upper idler gear. The upper idler gear is composed of 12 evenly-spaced notches with one additional notch offset to tell the ECU
that cylinder #1 is approaching top-dead-center (TDC).
The ECU detects the signal from the camshaft speed sensor at terminals A4 and E4 of ECU connector (X15).
The ECU uses this signal to determine which cylinder is approaching top dead center and determines camshaft speed. If there
is a problem with the crankshaft speed sensor, the ECU will use the camshaft speed sensor to determine engine timing. This
may require prolonged engine cranking to start the engine.
Engine Oil Pressure Switch (B6)— The engine oil pressure switch is a normally closed switch held open by the oil pressure
in the engine. When the oil pressure drops below specification, the switch closes and grounds terminal E3 of the ECU connector
(X15). If oil pressure is low for one second or more, the low oil pressure indicator illuminates on the display and a diagnostic
trouble code (DTC) is stored in memory.
Low oil pressure is due to low or no oil present.
Hydraulic Oil Filter Restriction Switch (B3)— This normally open switch applies ground to terminal J1 of connector (X16)
when closed. This switch closes when the hydraulic oil pressure differential at the filter is greater than specification and the
filter bypass valve opens. The ECU broadcasts the hydraulic oil filter restriction switch message across the controller area
network (CAN) to the EMU. When the switch closes, the EMU will illuminate the hydraulic oil filter restriction indicator light and
generate a diagnostic trouble code (DTC).
Air Filter Restriction Switch (B1)— This normally open switch applies ground to terminal E3 of connector (X16) when
closed. This switch closes when a restriction is detected. The ECU broadcasts the air filter restriction switch message across the
controller area network (CAN) to the EMU. When the switch closes, the EMU will illuminate the hydraulic oil filter restriction
indicator light and generate a diagnostic trouble code (DTC).
Start Relay (K1)— When the key switch is turned to the START position, current flows from the park brake switch (S2), to
terminal ST to S2 of the key switch, to terminal B3 of ECU connector (X16).
When the ECU detects this signal, and all other requirements are met, the ECU will provide a ground at terminal C2 of ECU
connector (X16) for the start relay (K1), energizing the relay. For more information on the start circuit, see Starting Circuit
Theory of Operation . (Group 9015-15.)
Glow Plug Relay (K2) and Fan Bypass Solenoid Valves 1 and 2 (Y33 and Y34)— The glow plugs are used to aid engine
starting performance in cold weather. The ECU provides power from terminal H4 to terminal 86 of the glow plug relay (K2),
energizing the relay. With the relay energized, battery power is supplied through the glow plug fuse (F9) and glow plug relay
(K2) to the glow plugs.
Glow plugs will be activated for up to 30 seconds or until engine speed is greater than 800—1000 rpm. After the engine
reaches 800 rpm or greater, the ECU will keep the glow plugs energized for an additional 10 seconds. When the glow plug relay
is energized, the WAIT TO START indicator will illuminate on the display. Glow plug activation is determined by taking the
coldest temperature from one of the following: ambient air temperature sensor (B24), engine coolant temperature sensor (B5),
hydraulic oil temperature sensor (B2), or the internal engine control unit (ECU) temperature.
Both fan bypass solenoid 1 (Y33) and fan bypass solenoid 2 (Y34) are in the same circuit from the engine control unit (ECU) as
the glow plug relay (K2). When the ECU energizes the glow plug relay during engine preheat and after engine startup, both fan
bypass solenoids are also energized.
When the fan bypass valves are energized, most of the hydraulic oil in the charge circuit is routed to the hydraulic oil tank. This
direct route to return reduces charge pressure in the system and effectively bypasses the hydraulic fan system and filter. A
small amount of necessary charge oil flow is provided to the hydrostatic pumps at engine startup. This action puts less load on
the charge pump and reduces engine load for cold weather starting.
Electronic Injectors (Y25—Y28, 2.4L [four cylinder] engine) or (Y25—Y29, 3.1L [five cylinder] engine)— The ECU
controls the injection timing and the amount of fuel injected by energizing and de-energizing the electronic injectors. For more
information on the electronic injectors, see PowerTech™ E 2.4L and 3.0L Diesel Engines . (CTM101019.)
Air Conditioner Switch (S19)— When the air conditioner switch is turned ON, power is also sent to the ECU terminal F1
connector (X16). This information is used to control fan speed. For more information on fan speed, see hydraulic fan operation.
Hydraulic Fan Operation— The proportional fan controls the cooling capacity of the cooling package by varying the speed of
the fan. The ECU automatically controls the speed of the fan by monitoring the following inputs:
B2—Hydraulic Oil Temperature Sensor


S19—Air Conditioner Switch
S35—Reversing Fan Switch (if equipped)
ECU outputs involved:
Y30—Hydraulic Fan Speed Solenoid

Y31—Hydraulic Reversing Fan Solenoid A (if equipped)
Y32—Hydraulic Reversing Fan Solenoid B (if equipped)
The ECM compares the information received from the inputs that are hard wired to itself and varies the fan speed as required.
The input calling for the highest fan speed shall be the controlling parameter. If one of the controlling parameters is invalid or
unavailable, maximum fan speed shall be commanded by the ECM.
The ECU drives the hydraulic fan speed solenoid (Y30) at terminal J4 and is grounded at terminals C1 and D2 of connector
(X16) with a pulse width modulation (PWM) duty cycle between 100% for full fan speed and 18% for the minimum fan speed
engine running. If any temperature is invalid, the ECU commands 100% duty cycle.
Below 12°C (54°F) the fan will be driven at 0% duty cycle (0 rpm) when the engine is in stop or start mode, and for the first 7
seconds of run mode, to reduce cold start load.
The variable speed hydraulic fan is controlled based on the sensor temperatures and the air conditioner switch.
Desired Temperatures
Temperature Sensor Inputs Desired Temperatures
95°C
(203°F)
82°C
B2—Hydraulic Oil Temperature Sensor
(180°F)
45°C—65°C
(113°F—149°F)
With the air conditioner switch is ON, and hydraulic oil temperature above 12°C (54°F) the fan speed will rise. If the hydraulic
temperature is below 12°C (54°F), and the air conditioner switch is ON the fan speed will not be effected.
Reversing Fan—If Equipped: The reversing fan is controlled by a three position external rocker switch (off, auto or manual
mode), which is connected to the EMU and communicated to the ECU over controller area network (CAN). For more
information, see Engagement and Monitor Unit (EMU) Circuit Theory of Operation . (Group 9015-15.)
The variable speed reversing fan operation can be activated in two ways, automatic or manual mode.
In automatic mode, the fan will reverse every 20 minutes when the reversing fan switch (S35) is in the automatic position and
hydraulic oil temperature is above 12°C (54°F).
In manual mode, the fan may be reversed by pressing the reversing fan switch (S35) momentarily to the manual position. If the
engine is running and hydraulic oil temperature is above 12°C (54°F), the fan will reverse.
If this switch is held for more than 60 seconds the manual reversing mode will be deactivated and a DTC will set.
Engagement and Monitor Unit (EMU) Circuit Theory of Operation
Engagement and Monitor Unit (EMU) Circuit Schematic (1 of 2)
LEGEND:
G1 Battery
K1 Starter Relay
K8 Ignition Relay
M1 Starter Motor
S1 Key Switch
S4 Seat Switch
S8 High Flow Switch
S13 Cab Door Switch
W21 Starter Ground
Engagement and Monitor Unit (EMU) Circuit Schematic (2 of 2)
LEGEND:
B15 Auxiliary Proportional Switch
K7 Air Conditioner Compressor Clutch Relay
S25 Two Speed Switch
S28 Auxiliary Flow Set Switch
X22 Right Control Lever 12-Pin Connector
X24 Left Control Lever 8-Pin Connector
The engagement and monitor unit (EMU) (A2) uses information from the machine sensors and switches to display information
to the operator. The EMU also uses operator input from switches and sensors to control certain machine functions. The EMU
also uses information from other controllers and sensors, via the controller area network (CAN), to aid in operation.
Operator interlocks to enable hydrostatic and hydraulic systems

Operator display of information
Audible alarm to alert the operator
Main auxiliary hydraulics
High/low (two speed) shifting of the hydrostatic motors—if equipped
The EMU communicates with the other controllers using the controller area network CAN.
Engine Status
Engine speed information is sent to the EMU from the engine control unit (ECU) over the (CAN). The ECU uses the engine
crankshaft speed sensor (B22) to calculate engine speed.
The EMU determines that the engine is running if the engine speed sent from the ECU is above 800 rpm, and the key switch is
ON. The engine is determined to be off when the engine speed is less than 30 rpm and the key switch is OFF.
Remote Start Logic
On manual control machines, the remote start box can be used to start and stop engine, control engine speed, and engage and
disengage park brake with cab raised and in locked position.
When the machine is started with the remote start box, power is sent to pin L of EMU connector (X43), which signals to EMU
that remote start box is in use.
The remote start diode (V1) is used to keep switched power from the machine from feeding back into the signal sent to pin L of
EMU connector (X43).
Auto Idle
Auto idle can be enabled or disabled in the EMU menu. See Engagement and Monitor Unit Operation . (Group 9015-16.)
Auto idle automatically commands the engine to slow idle speed if the engine is left running at a speed greater than slow idle
for more than 60 seconds, the operator is not in the machine, and auxiliary hydraulics are not enabled.
The request for engine idle speed is sent to the engine control unit (ECU) through the controller area network (CAN).
Auto idle becomes active if ALL of the following are true for longer than 60 seconds:
Auto idle is enabled in the EMU.

Engine is running.
It has been more than 30 seconds since engine start.
Operator is out of the seat.

Engine speed control dial or engine speed control pedal is more than 5% above idle.
Auxiliary hydraulics are not enabled.
→NOTE:
AUTO IDLE is displayed on the EMU when machine is in auto idle mode.
To deactivate auto idle, rotate engine speed control dial to slow idle then back to desired engine speed.
→NOTE:
Auto idle is also deactivated when engine is shut off.
Interlock Logic
→NOTE:
Windshield wiper motor (M4) connector must be connected for proper operation of the cab door switch
(S13).
The seat switch (S4) followed by the interlocking seat bar switch (S5) and cab door switch (S13) must be connected to system
voltage for the engagement and monitor unit (EMU) to allow the RUN input and RELEASE input to enable the hydraulic and
hydrostatic functions and to release the park brake. On machines equipped without a cab door, or the cab door is removed,
terminal C of the EMU J1 connector (X41) will not be grounded. When ground is not present at terminal C the EMU disregards
the status of the door switch (S13).
When the park brake switch (S2) is in the RUN position, system voltage is connected to terminal F of EMU J2 connector (X42).
This input, along with the seat interlock signal, allows the EMU to enable hydraulics. The EMU sends power to the for the boom
spool lock (Y2), bucket spool lock (Y3), and the port lock solenoids (Y4) on the control valve from terminal H of the EMU J1
connector (X41). The EMU also sends a hydraulic enable message over the controller area network (CAN), but does not release
the park brake.
When the RELEASE input at terminal K of EMU J2 connector (X42) is momentarily connected to system voltage from the park
brake switch (S2), the EMU outputs power from terminal P of EMU J1 connector (X41) to the park brake solenoid (Y5) to release
the park brake. The EMU also sends a hydrostatic enable message over the CAN.
If the seat switch drops power to the EMU for more than one second after either the hydraulic or hydrostatic and park brake
outputs have been enabled, these outputs are turned off. This disables the hydraulics, hydrostatics, and engages the park
brake. The one second delay is to prevent the hydraulics from disengaging and the park brake from engaging if the operator
bounces in the seat while driving over rough terrain.
If the interlocking seat bar switch or cab door switch momentarily drops power to the EMU after either the hydraulic or park
brake outputs have been enabled, the outputs are turned off. This disables the hydraulics and engages the park brake.
Once power has been lost from the seat switch (S4) or interlocking seat bar switch (S5) to the EMU, power must be
reestablished from the seat switch (S4) first and then the interlocking seat bar switch (S5). This sequence must be followed for
the EMU to allow the enabling of the hydraulic and hydrostatic functions to release the park brake.
The park brake output from the EMU must always be off when the engine is not running.
Auxiliary Hydraulics Operation
→NOTE:
The engagement and monitor unit (EMU) provides power to the two auxiliary pilot solenoids on the control valve: Auxiliary port
(male) solenoid (Y23) and auxiliary port (female) solenoid (Y24). Auxiliary hydraulics are enabled based on similar logic used
for enabling the boom and bucket hydraulic functions (see Interlock Logic, above, and Auxiliary Hydraulic Interlock, below).
If the operator actuates the proportional auxiliary control switch (B15) in the right joystick handle, a signal is sent to the EMU.
The EMU converts this signal and energizes the appropriate auxiliary pilot solenoid to produce flow to the attachment in the
requested direction and volume. When the operator stops actuating the proportional switch roller, the roller spring-returns to
center position and auxiliary outputs are turned off. Associated with this function is the flow set switch (S28) in the right control
lever. This switch gives the operator control to set the flow on continuously or turn off continuous flow.
Auxiliary Hydraulic Interlock
The auxiliary hydraulic interlock function ensures that the operator is present in the machine and the door is closed before
enabling the auxiliary hydraulics for attachments. After this, the operator can use the auxiliary hydraulic override switch (S21)
to run auxiliary hydraulics without being in the seat.
If the auxiliary hydraulic override switch (S21) is pressed, system voltage is momentarily applied to terminal B of EMU J2
connector (X42), activating the auxiliary hydraulic override.
If the proportional auxiliary control switch (B15) is open (centered) and the auxiliary hydraulic override switch (S21) is pressed,
the EMU enters bypass mode and AUX HYDRAULIC BYPASS displays on the display. After AUX HYDRAULIC BYPASS appears on
the display, the operator can exit the machine (interlocking seat bar switch open) for up to 15 seconds. If the operator exits the
machine within the 15 seconds, auxiliary hydraulics remain enabled. If the operator does not exit the machine within 15
seconds, the EMU exits the bypass mode.
The EMU remains in bypass mode until the interlock logic is performed.
Auxiliary Hydraulic Calibration
The EMU controls the calibration of the threshold current needed to actuate the auxiliary pilot oil solenoids. See Auxiliary
Hydraulics Calibration . (Group 9015-20.)
Engine Coolant Temperature Sensor (B5)
The engine control unit (ECU) transmits the engine coolant temperature information across the controller area network (CAN)
data line to the engagement and monitor unit (EMU). The EMU uses this information to determine the position of the pointer on
the engine coolant temperature gauge. For more information on engine coolant temperature sensor, see Electrical Component
Checks . (Group 9015-20.) The EMU then moves the pointer to a corresponding location to indicate the virtual temperature as
indicated in the following table:
Engine Coolant Temperature Gauge Position/Temperature
Gauge Position—Percentage Temperature
0 -18°C (0°F)
12.5 21°C (70°F)
25 77°C (171°F)
37.5 88°C (190°F)
87.5 116°C (241°F)
100 121°C (250°F)
Fuel Level Sensor (B4)
The fuel level sensor is a variable resistance fuel level sensor. The resistance is sensed at terminal L of the engagement and
monitor unit (EMU) J1 connector (X41). Information from this sensor is used to display the fuel level to the operator and to warn
the operator when the fuel level is low. When fuel is low, the operator will be warned by a series of three warnings. The first
and second warnings consist of a message on the EMU display and three beeps of the EMU warning alarm. The third warning
starts immediately after the second warning and consists of a message on the EMU display and a single beep of the EMU
warning alarm every 60 seconds. The message displayed on the EMU display is LOW FUEL until the SELECT or MENU buttons
are pushed. For more information on fuel level sensor, see Electrical Component Checks . (Group 9015-20.)
Air Conditioner Compressor Cutout
When engine coolant temperature is 108°C (226°F) or greater, the engagement and monitor unit (EMU) disables the air
conditioning compressor clutch relay (K7). This stops the air conditioning compressor from operating and A/C OFF appears in
the engagement and monitor unit display. This will reduce the load on the engine and allow for cooler air to be drawn through
the engine coolant radiator and hydraulic oil cooler. When the engine coolant temperature drops below 100.6°C (213°F), the
engagement and monitor unit will enable the air conditioning compressor clutch relay (K7) allowing the air conditioning
compressor to operate.
Two Speed Circuit—If Equipped
Machines can be optionally equipped with two speed motors. The operator uses the two speed switch (S25) on the left joystick
to shift between low and high motor speeds. Pressing the momentary (trigger) switch applies power to terminal M of
engagement and monitor unit (EMU) J2 connector (X42), and the EMU toggles between the low and high range selection for
both hydrostatic motors by energizing the two speed solenoid (Y6).
When the two speed solenoid (Y6) is energized, hydraulic pressure is provided to shift both left and right motors to high speed
range (low displacement). When the two speed solenoid is de-energized, the solenoid removes hydraulic pressure to the
motors and the motors return to the low speed range (high displacement) mode.
Reversing Fan—If Equipped
Reversing fan is controlled by a three position external rocker switch, which is connected to the engagement and monitor unit
(EMU). The reversing fan option switches the direction of the cooling fan to help clear the cooling package of debris buildup.
The reversing fan switch (S35) applies power from switched power 10 amp fuse (F15) to terminal D of EMU J2 connector (X42)
for automatic mode or terminal C of EMU J2 connector (X42) for manual mode. The automatic position on the switch is a detent
position and the manual mode position on the switch is a momentary position. The request for reversing fan is then sent to the
engine control unit (ECU) through the controller area network (CAN).
High Flow—If Equipped
High flow can either be On or Off by pressing the high flow switch (S8). The high flow switch is a normally open momentary
switch. When the switch is pressed, power from switched power 10 amp fuse (F15) flows to terminal M of EMU J3 connector
(X43), activating high flow. When the high flow switch is pressed, power is directed again to the EMU, deactivating high flow.
The high flow valve is controlled by the high flow solenoid (Y7), an electric solenoid powered from terminal S of EMU J1
connector (X41).
Backup Alarm Circuit Theory of Operation
Backup Alarm Circuit Schematic

LEGEND:
G1 Battery
H2 Backup Alarm
K4 Accessory Relay
M1 Starter Motor
S1 Key Switch
W21 Starter Ground
When both steering levers are moved in the reverse direction, left reverse switch (S10) and right reverse switch (S11) are
closed. This applies power to the backup alarm (H2), providing an audible warning to bystanders.
Quik-Tatch Circuit Theory of Operation
Quik-Tatch™ Circuit Schematic

LEGEND:
F13 Quik-Tatch Inline 30 A Fuse
K13 Quik-Tatch Relay (LOCK)
K14 Quik-Tatch Relay (UNLOCK)
Section 9015 - ELECTRICAL SYSTEM Group 16: Monitor Operation
M1 Starter Motor
M10 Quik-Tatch Motor
W21 Starter Ground
IMPORTANT:
Damage to electric Quik-Tatch™ motor will occur if motor is immersed in liquid. DO NOT IMMERSE IN
LIQUID.
→NOTE:
Electric Quik-Tatch is optional equipment.
When the operator presses the Quik-Tatch ™ switch, current is directed by the switch to flow through either the lock, or unlock
relay which activates the electric motor on the Quik-Tatch cylinder. Each end of the cylinder is attached to one of the Quik-
Tatch latches and takes the place of the standard manual levers. The cylinder will extend or retract, depending on whether the
operator is latching or unlatching the attachment.
Group 16 - Monitor Operation

Engagement and Monitor Unit Operation
The engagement and monitor unit (EMU) can be used to display vital operating information, machine hours, diagnostic trouble
codes (DTCs), diagnostics and to calibrate machine systems. It can also be used to lock the machine using an anti-theft
security system (if equipped).
Power Up
The EMU can be powered up by turning the seat switch ON (sitting in the seat) or turning the key switch ON.
Upon initial power up, the EMU runs a self test to ensure that all functions are operating. If powered by the seat switch, the
EMU self test turns the backlighting on, turns on all LCD pixels for 1 second, and turns on all indicator lights for 5 seconds. If
powered by the key switch only, the EMU self test turns the backlighting on, turns on all LCD pixels for 1 second, turns on all
indicator lights for 5 seconds, and then goes to normal runtime screens. The gauges calibrate to the right post, go to vertical
position for 1 second, and then go to their runtime positions. If the key switch is turned ON after the seat switch is ON, the
gauges calibrate to the right post, and then go to their runtime positions.
After the self test, the display initially reads TMC BY JOHN DEERE for 1.5 seconds before showing the machine model and
speeds for 3 seconds. If the anti-theft system has not been enabled or is not active, the display defaults to the runtime screen.
If the anti-theft system is enabled and unlocked, the display defaults to the runtime screen. If the anti-theft system is enabled
on the machine, the operator is prompted to enter their code.
Switch Inputs
Four push-buttons on the left side of the EMU are provided for operator input. The switches are labeled with a menu icon
(MENU), a left-pointing arrow (BACK), a down-pointing arrow (NEXT), and a check mark symbol (SELECT).
Menu Navigation
After the initial 5 second power up sequence, the operator can navigate through the various menus using the four EMU
buttons. Press the MENU button to access the menus from the runtime display.
Pressing and holding MENU for 5 seconds accesses the service menu. The service menu can be used to display diagnostic
information, clear diagnostic trouble codes, and calibrate machine systems. Once the service menu has been accessed, this
menu remains accessible until power on the EMU is cycled off.
For more information, see Engagement and Monitor Unit Data Items and see Engagement and Monitor Unit Service Menu
Operation . (Group 9015-16.)
Run Data Items
The run data items are the default display when the engagement and monitor unit is powered up. The run data items can also
be displayed while cycling through the menu items by pressing the MENU button, or by pressing MENU at anytime while in a
submenu. Pressing SELECT while viewing a run data item scrolls through all the run data items.
Hours
Volts
Job Hours
Hydraulic Oil Temperature
Engine Temperature
Engine RPM
Hour Meter
The EMU updates, maintains, and displays accumulated machine hours. Hours are displayed to the nearest tenth hour. If
needed, the current hour meter value can be transferred to a new EMU. See Engagement and Monitor Unit Initial Configuration
. (Group 9015-16.)
Diagnostic Trouble Codes (DTCs)
If a DTC becomes active, a pop-up message CHECK SERVICE CODE appears in the EMU display. The code menu displays any
DTCs that are present in the machine. Each active DTC is stored immediately upon occurrence, provided the code is not
already saved in memory. Any DTC still active is immediately stored again. For more information, See Reading Diagnostic
Trouble Codes (DTCs) . (Group 9015-20.)
Monitor Menu
The Monitor Menu allows user to choose language and units format for their monitor.
[1] - Press MENU to display EMU main menu.
[2] - Press NEXT until MAIN MENU MONITOR displays.
[3] - Press SELECT to change monitor settings.
[4] - MONITOR UNITS displays, press SELECT to change monitor units setting or press NEXT to display MONITOR LANGUAGE.
a. Press NEXT to cycle between ENGLISH and METRIC unit settings.

b. Press SELECT to change monitor units setting.
Selected monitor unit setting displays for 2 seconds then returns to runtime display.
[5] - When MONITOR LANGUAGE displays, press SELECT to change monitor language settings.
a. Press NEXT to cycle between monitor language settings.

b. Press SELECT to change monitor language setting.
Selected monitor language setting displays for 2 seconds then returns to runtime display.
Job Timer
The job timer is used to accumulate the engine hours on a particular job. If the key switch is turned off, the job timer value is
saved and will continue from that point the next time the machine is started. The operator can select the job timer to display or
clear these accumulated hours. The job timer function is similar to the hour meter except it can be reset to zero through the
menu. For more information, see Engagement and Monitor Unit Service Menu Operation . (Group 9015-16.)
Auto Idle Enable or Disable
Auto idle can be enabled or disabled in the EMU menu.
[1] - Press MENU to display EMU main menu.
[2] - Press NEXT until MAIN MENU AUTO IDLE displays.
[3] - Press SELECT to enter auto idle sub menu.
[4] - Press NEXT to cycle between DISABLE AUTO IDLE and ENABLE AUTO IDLE displays.
[5] - Press SELECT when desired setting is displayed.
[6] - Selected setting is displayed for 2 seconds then returns to normal runtime display.
For more information, see Auto Idle Operation . (Operator′s Manual.)

Anti-Theft Enable or Disable
The optionally-enabled anti-theft security system within the EMU provides a basic level of machine theft protection. When the
anti-theft security system is enabled, the machine can be unlocked and locked with the use of either a 3-digit or 5-digit security
code (depending on how the system is configured). This security code, along with the machine key switch, is necessary to start
and run the engine. For more information, see Anti-Theft Security System Operation—If Equipped and see Anti-Theft Security
System Configuration—If Equipped . (Group 9015-16.)
Anti-Theft is enabled or disabled through the service menu. If Anti-Theft is not enabled, Anti-Theft submenu is only available in
service menus. If Anti-Theft is enabled, Anti-Theft submenu is available in both operator menus and service menus. For more
information, see Anti-Theft Security System Enable—If Equipped . (Group 9015-16.)
System Interlocks
The seat interlock function ensures that the operator has lowered the interlocking seat bar each time the operator enters the
machine and prior to enabling functions that require operator presence in the machine. The park brake interlock function
ensures that the operator is present in the machine prior to enabling park brake release. The hydraulic interlock function
ensures that the operator is present in the machine and the door is closed prior to enabling the hydraulics for the boom and
bucket functions. The auxiliary hydraulic interlock function ensures that the operator is present in the machine and the door is
closed prior to enabling the auxiliary hydraulics for attachments. After the auxiliary hydraulic interlock occurs, the operator can
use the override mode to run auxiliary hydraulics without being in the seat. For more information, see Engagement and Monitor
Unit (EMU) Circuit Theory of Operation . (Group 9015-15.)
Remote Start Interlock
A remote start box can be used for performing service functions on the machine. For more information, see Engagement and
Monitor Unit (EMU) Circuit Theory of Operation . (Group 9015-15.)
Engagement and Monitor Unit Data Items

Run Data Items
The run data items are the default display when the engagement and monitor unit is powered up. The run data items may also
be displayed by cycling through the menu items by pressing the MENU button, or by pressing MENU at anytime while in a
submenu. Pressing SELECT while viewing a run data item will scroll through all the run data items.
Hours
Volts
Job Hours
Engine Temperature
Engine RPM
Diagnostic Display Items
The diagnostic display items are available under the service menu in the engagement and monitor unit (EMU).
[1] - Start engine or turn key switch to ON.
[2] - Press and hold the MENU button for 5 seconds to access the service menu.
[3] - Press NEXT until the display shows MAIN MENU DIAGNOSTICS.
[4] - Press SELECT to enter the diagnostics submenu.
[5] - Use the NEXT and SELECT buttons to navigate through the diagnostic display items.
The following are diagnostic display items and (reading information) available using the EMU.
Switches Diagnostic Display Items
• Seat Switch (ON or OFF)

• Lap Bar (ON or OFF)
• Key Start (ON or OFF)
• Door Switch (ON or OFF)
• Park Brake Rel (release) (ON or OFF)
• Park Brake Run (ON or OFF)
• Aux Flow Set (auxiliary) (ON or OFF)
• Over Ride (auxiliary) (ON or OFF)
Diagnostics
• Engine Oil Press (pressure) (ON or OFF)
Switches
• Air Filter Res (restriction) (ON or OFF)
• Hyd Oil Filter (ON or OFF)
• Door Present (ON or OFF)
• 2-Speed (ON or OFF) (if equipped)
• Fan Reverse (ON or OFF) (if equipped)
• Fan Auto (ON or OFF) (if equipped)
• High Flow (ON or OFF) (if equipped)
• AC Switch (ON or OFF) (if equipped)
Sensors Diagnostic Display Items
• Fuel Level Sender (% and sender voltage)

• Engine Coolant Temp (temperature and sensor voltage)
• Hyd Oil Temp (temperature and sensor voltage)
Diagnostics • Foot Throttle (% and sensor voltage) (if equipped)
Sensors • Hand Throttle (% and sensor voltage)
• Manifold Air Temp (temperature and sensor voltage)
• Ambient Air Temp (temperature and sensor voltage)
• Fuel Pressure (pressure and sensor voltage)
Speeds Diagnostic Display Items
Diagnostics
• Engine (rpm)
Speeds
EMU Outputs Diagnostic Display Items
• 2-Speed (ON or OFF)

• Current (2 speed) (amperage)
• Aux Extend (amperage)
Diagnostics • Aux Retract (amperage)
EMU Outputs • AC Clutch Relay (ON or OFF)
• Park Brake Sol (solenoid) (ON or OFF)
• Audible (EMU) Alarm (ON or OFF)
• High Flow Sol (solenoid) (ON or OFF) (if equipped)
ECU Outputs Diagnostic Display Items
• Starter Relay (ON or OFF)

Diagnostics • Fan Speed (0—100%) (if equipped)
ECU Outputs • Fan Rev Sol 1 (ON or OFF) (if equipped)
• Fan Rev Sol 2 (ON or OFF) (if equipped)
EMU Power Diagnostic Display Items
• Switched (voltage)
Diagnostics
• Unswitched (voltage)
EMU Power
• Sensor Power Out (voltage)
ECU Power Diagnostic Display Items
• Switched (voltage)
Diagnostics • Unswitched (voltage)
ECU Power • Sensor Supply 1 (voltage)
• Sensor Supply 2 (voltage)
Controller Info Diagnostic Display Items
• EMU (software part number ATxxxxxx)

• SW VER (software version number X.X.X)
Diagnostics
• ECU (software part number ATxxxxxx)
Controller Info
• SW VER (software version number X.X.X)
• EMU Tractor VIN (tractor VIN number)
Engagement and Monitor Unit Display Messages

The engagement and monitor unit (EMU) automatically displays a message for specific machine situations and certain
diagnostic trouble codes (DTCs). Depending on machine situation or if a DTC is initially active, a message displays on the EMU
until the situation changes, the DTC is resolved, or the operator presses any button on the EMU.
If multiple display messages are generated, the one with the highest EMU priority displays. Pressing any button on the EMU
closes the displayed message, allowing the next message to display in order of EMU importance until all generated messages
have been displayed.
Engagement and Monitor Unit Display Messages
Display Message Message Trigger
A/C OFF Air conditioning has shut off because engine temp > 108°C (226°F). ECU DTC 000110.00 is triggered.
Auto Idle Auto Idle is active.
Aux Hydraulic
Auxiliary hydraulics are in Override mode.
Bypass
Check Service
A DTC is active that should trigger the Check Service Code monitor message.
Code
Operator attempted to release park brake without door closed (cab machines). EMU DTC 003413.04 is triggered (non-cab
Door Open
machines).
Engine Air Filter

Engine air filter restriction warning indicator comes on and indicator not in bulb check . ECU DTC 000107.00 is triggered.
Restriction
Engine
ECU DTC 001569.31 is triggered.
Derate
Engine Oil
Engine oil pressure indicator light comes on after engine is running. ECU DTC 000100.01 is triggered.
Pressure Low
Engine Temp
Engine temperature goes to the red zone of gauge and the engine is running. ECU DTC 000100.00 is triggered.
High
Fasten Seat Belt

Operator attempted to release park brake without fastening seat belt and lowering interlocking seat bar.
Lower Lapbar
High Voltage Battery voltage warning indicator comes on after engine is running. EMU DTC 000158.00 is triggered.
Hyd Oil Filter

Hydraulic oil filter restriction warning indicator comes on after EMU startup. ECU DTC 001713.00 is triggered.
Restriction
Hydraulic Oil
Hydraulic oil temperature indicator light comes on after EMU startup. ECU DTC 001508.00 is triggered.
Temp High
Hydraulic Temperature Too Low For

Hydraulic oil temperature is below specification for two speed shift to occur (318D and 320D machines only).
Shift
Low Fuel Fuel level low after engine is running.
Low Voltage Battery voltage warning indicator comes on after engine is running. EMU DTC 000158.01 is triggered.
Ready to
Glow plug or starter cool down wait to start time has elapsed and the engine is ready to start.
Start Engine
Remote Start
Remote start box installed.
Connected
Service Menu When the menu button is held for 5 sec. the Service Menu will appear.
Set Park Brake

The seat switch is active, the key switch is ON, and the engine is not running. (Park brake switch must be ON to start engine.)
To Start Engine
Wait to Start XX Sec Starter has been on for more than 30 sec.
(Glow Plug Icon) and Wait to Start XX

Key switch is on and glow plug wait to start time has not elapsed.
Sec
Engagement and Monitor Unit Service Menu Operation

The service menu allows access to additional items not available in the normal menu system. To enter the service menu, press
and hold the MENU button on the engagement and monitor unit (EMU) for 5 seconds.
The following are several menu items available within the service menu. For general EMU operation, see Engagement and
Monitor Unit Operation . (Group 9015-16.)
Clearing Diagnostic Trouble Codes (DTCs)
Use the service menu to clear diagnostic trouble codes stored by the EMU. See Reading Diagnostic Trouble Codes (DTCs) .
(Group 9015-20.)
[1] - Once in the service menu, press the NEXT button until MAIN MENU CODES displays.
[2] - Press SELECT. The EMU display shows CODES ACTIVE.
[3] - Press NEXT until CODES CLEAR displays.
[4] - Press SELECT to clear stored DTCs.
CODES CLEARED displays for 2 seconds before the EMU returns to the last menu item.
Monitor Settings
Using the service menu, several monitor settings can be configured:
Hide/Unhide Menu—When the menu is hidden the menu is not accessible; only the runtime data is visible to the operator.
Restore Defaults—Set monitor back to defaults of English for language, English units of measure, and menu unhidden.
Contrast—Adjust display contrast (settings are 1—7). Press BACK to decrease contrast, press NEXT to increase, and press
SELECT to store selected contrast setting.
Job Timer Hide/Unhide
The basic start and reset functions of the job timer are available from the default main menu. The ability to hide or unhide the
job timer function is only available from the service menu.
[1] - Once in the service menu, press the NEXT button until MAIN MENU JOB TIMER displays.
[2] - Press SELECT. The EMU display shows the current job timer setting, either JOB TIMER HIDE or JOB TIMER UNHIDE.
[3] - Use the NEXT button to toggle to the appropriate job timer setting.
[4] - Press SELECT to either hide or unhide the job timer, as selected.
The selected setting displays for 2 seconds before the EMU returns to the last menu item.
Diagnostics
The diagnostic submenu can be used to display diagnostic items available using the service menu in the EMU. For more
information, see Engagement and Monitor Unit Data Items . (Group 9015-16.)
Anti-Theft
Anti-Theft provides a way to secure the machine and prevent unauthorized use. Anti-Theft is enabled or disabled through the
service menu. If Anti-Theft is not enabled, Anti-Theft sub menu is only available in service menus. If Anti-Theft is enabled, Anti-
Theft sub menu is available in both operator menus and service menus. For more information, See Anti-Theft Security System
Enable—If Equipped . (Group 9015-16.)
Machine Calibration
The auxiliary calibration procedure calibrates the control valve threshold values for the auxiliary functions of the machine. For
more information, See Auxiliary Hydraulics Calibration . (Group 9015-20.)
Engagement and Monitor Unit Initial Configuration

→NOTE:
For optimal machine performance, ensure that latest software is installed in the engagement and monitor
unit (EMU) when installing a new EMU. Download latest software with Service ADVISOR ™ . See Service
ADVISOR™ Connection Procedure . (Group 9015-20.)
Hour Meter Configuration

The following procedure is used to transfer the current hour meter value to a new engagement and monitor unit.
[1] - Record current hour meter value from original engagement and monitor unit.
[2] -
→NOTE:
The new engagement and monitor unit (EMU) allows 20 hours of initial runtime in which to input existing
hour meter value. If the value is not entered during the initial 20 hours of runtime, the EMU hour meter
value automatically sets to reflect runtime accumulated since installation of new EMU.
On initial start-up, the new engagement and monitor unit displays SELECT TO SET HOURS.
[3] -
→NOTE:
There is no time-out on the SELECT TO SET HOURS screen. Press SELECT to set the hour meter value or
any other button to display engagement and monitor unit normal data items.
Press SELECT to set the hour meter value for the new engagement and monitor unit.
[4] - Engagement and monitor unit displays 0 0 0 0 0. The last digit is flashing.
[5] -
→NOTE:
The ones digit is set first, followed by tens, hundreds, thousands and ten thousands digits in that order.
Using the NEXT and BACK buttons, input the existing hour meter value to the nearest full hour (no tenths).
a. Press and release NEXT to advance the number displayed in the active (flashing) field. The NEXT button increments the
current digit and “rolls over” from 9 to 0.
b. Press and release BACK to accept the number displayed (flashing) in the active field and shift the active field to the next
digit to the left.
c. If an incorrect value is entered and the active field advanced, continue to press and release BACK button until the
incorrect value is in the active field. Correct the value using the NEXT button.
[6] - Once the existing hour meter value has been entered, press SELECT to store these values.
[7] - Engagement and monitor unit display shows VERIFY XXXXX.X HRS (XXXXX.X HRS is the entered hour meter value).
[8] - If the displayed value is correct, press SELECT to store the value permanently. The engagement and monitor unit displays
HOURMETER SAVED before returning to the normal runtime screen.
If the displayed value is not correct, press BACK or NEXT to edit the hour meter value.
Anti-Theft Security System Operation—If Equipped

IMPORTANT:
When providing operator security codes to machine users, owners should not provide operators with the
default codes. Instead, owners should first change the default operator security codes to other values
before providing codes to machine users. See Anti-Theft Security System Configuration—If Equipped .
(Group 9015-16.)
→NOTE:
On a locked machine, engine can be started but will shutoff after 3 seconds.
Locking the Machine (Operator and Owner)
→NOTE:
On a locked machine, engine can be started but will shutoff after 3 seconds.
There are three different locking methods available with the anti-theft security system. See Anti-Theft Security System
Configuration—If Equipped . (Group 9015-16.)
Prompt for Lock

Auto Lock—5 min.
Auto Lock—60 min.
Prompt for Lock
[1] - Turn key switch to OFF.
[2] -
→NOTE:
If you do not press SELECT to lock the machine within 20 seconds of turning key switch OFF, the
engagement and monitor unit (EMU) will NOT lock the machine.
The monitor display shows PRESS SELECT TO LOCK ATS.
[3] - Press the SELECT button within 20 seconds to lock the machine.
Auto Lock—5 Minutes
[2] - The monitor display shows 5 MIN AUTO LOCK LOCK NOW?
[3] - Machine remains unlocked for the next 5 minutes. After 5 minutes, a valid 3-digit or 5-digit security code, depending on
system configuration, is required for machine operation.
OR
Press SELECT to lock the machine immediately.
Auto Lock—60 Minutes
[2] - The monitor display shows 60 MIN AUTO LOCK LOCK NOW?
[3] - Machine remains unlocked for the next 60 minutes. After 60 minutes, a valid 3-digit or 5-digit security code, depending on
system configuration, is required for machine operation.
OR
Press SELECT to lock the machine immediately.
Unlocking the Machine (Operator and Owner)
[1] - Sit in the operator′s seat to power up the engagement and monitor unit.
[2] - Turn key switch to ON position.
[3] - The engagement and monitor unit (EMU) displays ENTER CODE 0 _ _ (3-digit system) or ENTER CODE 0 _ _ _ _ (5-digit
system).
[4] - Enter the appropriate security code:
a. Press the NEXT button or the BACK button to change the number displayed in the active (flashing) field. The NEXT button
increments the current digit; the BACK button decrements the current digit.
→NOTE:
Pressing the SELECT button to accept the last digit (third digit or fifth digit depending on system
configuration) processes the entered security code.
Press the SELECT button to accept the number displayed (flashing) in the active field and shift the active field to the next
digit to the right.
[5] -
→NOTE:
The anti-theft security system allows three attempts to enter a valid security code. After three attempts,
the key switch must be cycled OFF and ON to restart the process.
If a correct security code is entered, the monitor displays ANTITHEFT UNLOCKED for 2 seconds before the EMU returns to the
normal runtime display.
The display shows INVALID CODE if the security code was incorrect.
Anti-Theft Security System Configuration—If Equipped

IMPORTANT:
The default owner security code for the anti-theft security system is 111 for 3-digit security systems, and
00111 for 5-digit security systems. The default operator security codes are 000, 999, and 998 for 3-digit
security systems, and 00000, 00999, and 00998 for 5-digit security systems.
When providing operator security codes to machine users, owners should not provide operators with the
default codes. Instead, owners should first change the default operator security codes to other values
before providing codes to machine users. Refer to Changing an Operator or Owner Security Code in this
section for more information.
Once the anti-theft security system has been enabled, either as a factory installed option or field installation, the system must
be configured. Select the locking method and change the owner and operator security codes, as necessary.
Selecting the Locking Method
Complete the following procedure to select the locking method for the anti-theft security system. Only someone with the owner
security code can configure the locking method. There are four locking options available within the anti-theft security system:
Prompt for Lock—Machine only locks if selected during EMU shutdown.

Auto Lock, 5 min.—Machine is locked automatically 5 minutes after operator turns key switch to OFF position.
Auto Lock, 60 min.—Machine is locked automatically 60 minutes after operator turns key switch to OFF position.
Anti-Theft Off—Machine is not locked.
[1] - Press the MENU button on the engagement and monitor unit (EMU) to access the Main Menu.
[2] - Press the NEXT button until MAIN MENU ANTITHEFT displays.
[3] - Press the SELECT button to display ANTITHEFT CHANGE CODES.
[4] - Press the NEXT button to display ANTITHEFT LOCK MODE.
[5] - Press the SELECT button to display OWNER CODE 0 _ _ (3-digit system) or OWNER CODE 0 _ _ _ _ (5-digit system).
[6] - Enter the current owner security code.
b. Press the SELECT button to accept the number displayed (flashing) in the active field and shift the active field to the next
digit to the right.
→NOTE:
configuration) processes the entered security code. If the code is incorrect, INVALID OWNER CODE
appears on the monitor display.
The anti-theft security system allows three attempts to enter a valid security code. After three
attempts, the key switch must be cycled OFF and ON to restart the process.
The current locking method displays.
[7] - Press the NEXT button to display the appropriate locking method.
TURN ATS OFF

PROMPT TO LOCK
AUTO LOCK IN 5 MIN
AUTO LOCK IN 60 MIN
[8] - Press the SELECT button to select the displayed locking method.
[9] - The selected locking method displays for 2 seconds before the EMU returns to the normal runtime display.
Changing an Operator or Owner Security Code
IMPORTANT:
If you do not intend to use all three available operator security codes, change all codes to something
other then their default values. Leaving access to the machine with default codes is not recommended.
The following rules apply when changing security codes:
An operator security code can only be changed if that security code or the owner security code is used during the change
procedure.
The owner security code can be used to reset all codes back to their defaults by accessing the RESET ALL CODES menu
option.
The anti-theft security system resets all operator security codes and the owner security code to the default values when
the master security code is used to enable the system.
The owner security code can only be changed if the owner security code is used during the change procedure. The owner
security code must be entered before changing that code.
[4] - Press the SELECT button. Display shows CHANGE CODES OPERATOR 1 CODE.
[5] - If changing a different operator security code or the owner security code, press the NEXT button to display the
appropriate security code to change. Proceed to next step.
[6] - Press the SELECT button. Display shows ENTER CURRENT CODE 0 _ _ (3-digit system) or ENTER CURRENT CODE 0 _ _ _ _
(5-digit system).
[7] - Enter the current operator security code or owner security code for the code to be changed.
→NOTE:
configuration) processes the entered security code. If the code is incorrect, an error message
appears on the monitor display.
digit to the right.
[8] - Enter the new security code.
[9] - The new security code displays for 3 seconds before the EMU returns to the normal runtime display.
Resetting Operator and Owner Security Codes
[4] - Press the SELECT button. Display shows CHANGE CODES OPERATOR 1 CODE.
[5] - Press the NEXT button until CHANGE CODES RESET ALL CODES displays.
[6] - Press the SELECT button. Display shows ENTER OWNER CODE 0 _ _ (3-digit system) or ENTER OWNER CODE 0 _ _ _ _ (5-
digit system).
→NOTE:
appears on the display.
digit to the right.
[8] - The anti-theft security system resets the owner and three operator security codes to their defaults of “111”, “000”, “999”,
and “998”, respectively, for 3-digit security systems, and “00111”, “00000”, “00999”, and “00998” for 5-digit security systems.
[9] -
→NOTE:
If the owner code is not available, security codes can be reset using the master security code, which a
John Deere dealer can obtain through DealerNet. Complete the anti-theft security system enable
procedure to reset security codes using the master security code. See Anti-Theft Security System
Enable—If Equipped . (Group 9015-16.)
The default codes display before the EMU returns to the normal display mode menu.
Changing System Security Code Length
Use this procedure to select the length of security code to use with the anti-theft security system, either 3-digit or 5-digit. The
system default is 3-digit.
[4] - Press the NEXT button until ANTITHEFT NUMBER OF DIGITS displays.
[5] - Press the SELECT button. Display shows OWNER CODE 0 _ _ (3-digit system) or OWNER CODE 0 _ _ _ _ (5-digit system).
→NOTE:
appears on the display.
digit to the right.
[7] - The current Antitheft System is displayed, either SELECT TO ENABLE 3-DIGIT CODES or SELECT TO ENABLE 5-DIGIT
CODES. To change the selection, press the NEXT button to cycle between the different systems and then press the SELECT
button to activate. The anti-theft security system resets the owner and three operator security codes to their defaults of “111”,
“000”, “999”, and “998”, respectively, for 3-digit security systems, and “00111”, “00000”, “00999”, and “00998” for 5-digit
security systems.
Section 9015 - ELECTRICAL SYSTEM Group 20: References
Anti-Theft Security System Enable—If Equipped

Enable the Anti-Theft Security System
→NOTE:
Anti-theft security system is a factory purchased option. A master security code can be obtained from
John Deere using DealerNet. The current engine hour meter reading and the serial number are necessary
to obtain a master security code. The master security code is used to enable the anti-theft security
system option.
Complete the following procedure if the anti-theft security system was not activated at the factory.
[1] - Turn the key switch ON.
[2] - Press and hold the MENU button for 5 seconds to access the engagement and monitor unit (EMU) service menu.
[3] - Press the NEXT button until display shows MAIN MENU ANTITHEFT.
[4] - Press the SELECT button to display ANTITHEFT MASTER CODE.
[5] - Press the SELECT button.
[6] - Enter the correct master security code:
→NOTE:
Pressing the SELECT button to accept the third digit processes the entered security code. If the code
is incorrect, INVALID MASTER CODE appears on the display.
digit to the right.
[7] -
→NOTE:
The anti-theft security system locking method defaults to ANTITHEFT OFF and the machine is not
protected. The locking method must be configured to enable locking. See Anti-Theft Security System
Configuration—If Equipped . (Group 9015-16.)
If the entered master security code is correct, the display shows ANTITHEFT ACTIVATED for 1.5 seconds, followed by CODES
SET TO DEFAULT.
The anti-theft security system sets the system to UNLOCK and resets the owner and three operator security codes to their
defaults of “111”, “000”, “999”, and “998”, respectively.
[8] - The EMU returns to the normal runtime display.
Group 20 - References
Service ADVISOR™ Connection Procedure
This procedure explains how to connect Service ADVISOR ™ to the machine using an electronic data link (EDL) connection. The
controller area network (CAN) used on the machine requires an EDL connection.
[1] -
Service ADVISOR™ Connector

LEGEND:
X40 Service ADVISOR™ Connector
Remove cover from Service ADVISOR™ connector (X40) located in upper left hand corner of operator′s station.
[2] -
LEGEND:
1 EDL-to-Computer USB Cable
2 EDL
3 CED W1 Cable
Cables for Service ADVISOR™ Connection

Connect CED W1 Cable (3) to Service ADVISOR™ connector on machine.
[3] - Connect CED W1 Cable to EDL (2).
[4] - Connect EDL-to-Computer USB Cable (1) to EDL and to USB port on service computer.
[5] - Locate the service computer close to the machine, or in the operator′s station if diagnostics are to be performed while the
machine is operated.
[6] - Refer to Service ADVISOR™ system instructions to log into the service computer and take data readings from machine.
Reading Diagnostic Trouble Codes (DTCs)

Use Service ADVISOR ™ or engagement monitor unit (EMU) to view stored diagnostic trouble codes (DTCs).
For a list of DTCs:
EH and Manual Control Machines

See Engine Control Unit (ECU) Diagnostic Trouble Codes . (Group 9001-10.)
See Engagement and Monitor Unit (EMU) Diagnostic Trouble Codes . (Group 9001-20.)
EH Control Machines Only

See Hydraulic Control Unit (HCU) Diagnostic Trouble Codes . (Group 9001-30.)
See Left Joystick Controller (JSL) Diagnostic Trouble Codes . (Group 9001-40.)
See Right Joystick Controller (JSR) Diagnostic Trouble Codes . (Group 9001-50.)
Reading Diagnostic Trouble Codes (DTCs) with Engagement Monitor Unit (EMU)
[1] - Turn key switch ON.
[2] - Press MENU to view EMU main menu.
[3] - Press NEXT until MAIN MENU CODES displays.
[4] - Press SELECT.
[5] - CODES ACTIVE displays.
[6] - Press NEXT to toggle between CODES ACTIVE and CODES STORED.
[7] - Press SELECT to view DTC list (active or stored).
→NOTE:
If no codes are present NO ACTIVE CODES or NO STORED CODES appears on the display.
Press NEXT to scroll through list of codes.

Press SELECT button to view DTC details.
Press BACK to move up one menu level.
To clear stored DTCs, see Engagement and Monitor Unit Service Menu Operation . (Group 9015-16.)
Reading Diagnostic Trouble Codes (DTCs) with Service ADVISOR
Service ADVISOR—Diagnostic Trouble Codes

LEGEND:
1 Diagnostics Shortcut Bar
2 Connected Diagnostic Trouble Codes Folder
3 Readings Data Tab
4 Connected Diagnostic Trouble Codes Tab
[1] - Connect service computer to machine. See Service ADVISOR™ Connection Procedure . (Group 9015-20.)
[2] - Open Service ADVISOR and display appropriate model information.
[3] - Turn machine key switch ON.
[4] - From the shortcut bar, click Diagnostics to open the Diagnostics shortcut bar (1).
[5] - Click the Connected Diagnostic Trouble Codes folder (2).
[6] -
Connection Options Dialog Box

Select the Connect to Model(s) radio button in the Connection Options dialog box, and click OK .
[7] -
Select Readings Adapter Dialog Box (no machine selected)
Select Readings Adapter Dialog Box (machine previously selected)

LEGEND:
5 Available Adapters Drop-Down List
6 Selected Models List
7 Change Models Button
8 Connection Type
In the Select Readings Adapter dialog box, make sure the appropriate adapter is displayed. If not, select correct adapter
from drop-down list (5). Options include:
Electronic Data Link (EDL) Stand-alone USB Device

Electronic Data Link (EDL) Using Bluetooth
[8] - Make sure correct machine to connect to displays in the Selected Models list (6). If not, click the Change Selected
Models button (7) to select machine model from list.
[9] - Click OK to connect to machine.
[10] - After Service ADVISOR connects to machine, both the Readings Data tab (3) and Connected Diagnostic Trouble Codes
tab (4) display.
[11] - Double-click an underlined code on the Connected Diagnostic Trouble Codes tab to display a detailed description for
servicing that diagnostic trouble code.
[12] -
→NOTE:
Use the lock topic feature within Service ADVISOR to open multiple windows if machine is transmitting
more than one diagnostic trouble code. Refer to Service ADVISOR system instructions for using this
feature.
Click the Connected Diagnostic Trouble Codes tab (4) to select and view details for additional diagnostic trouble codes.
Electrical Component Checks

IMPORTANT:
orientation.
For switches, sensors, or relay specifications, see Electrical Component Specifications . (Group 9015-20.)
Electrical Component Checks

( 1 ) Key Switch (S1) Check
Action:
LEGEND:
1 B (battery)
2 I (ignition)
3 S1
4 A (accessory)
5 S2
Key Switch
Remove switch from harness. Use multimeter to check for continuity.
Pins 1 and 4 in the Run position.

Pins 1 and 2 in the Start position.
Pins 3 and 5 in the Start position.
Result:
YES:Switch is OK.
NO:Switch has failed. Replace.
( 2 ) Park Brake Switch (S2) Check
Action:
LEGEND:
1 Pin 1
2 Pin 2
4 Pin 4
5 Pin 5
6 Pin 6
Park Brake Switch

Pins 5 and 6 in the Engaged position.

Pins 5 and 4 in the Release position.
Pins 1 and 2 in the Release position.
Is continuity measured?
Result:
YES:Switch is OK.
( 3 ) Work Lights Switch (S6) Check
Action:
LEGEND:
2 Pin 2
3 Pin 3
5 Pin 5
6 Pin 6
Work Lights Switch

Pins 2 and 3 in the front work lights and tail lights position.
Pins 2 and 3 in the front and rear work lights and tail lights position.
Pins 5 and 6 in the front and rear work lights and tail lights position.
Result:
YES:Switch is OK.
( 4 ) Dual Flasher Switch (S7) Check
Action:
LEGEND:
2 Pin 2
3 Pin 3
Dual Flasher Switch

Pins 2 and 3 in the ON position.

Result:
YES:Switch is OK.
( 5 ) High Flow Switch (S8) Check
Action:
LEGEND:
2 Pin 2
3 Pin 3
High Flow Switch


Result:
YES:Switch is OK.
( 6 ) Blower Speed Dial (S9) Check
Action:
LEGEND:
1 Pin 1
2 Pin 2
3 Pin 3
4 Pin 4
B Pin B
Air Conditioner and Heater Blower Speed Dial

Pins B and 1 in low speed.

Pins B and 2 in medium low speed.
Pins B and 3 in medium high speed.
Pins B and 4 in high speed.
Result:
YES:Switch is OK.
( 7 ) Air Conditioner Switch (S19) Check
Action:
LEGEND:
2 Pin 2
3 Pin 3
Air Conditioner Switch


Result:
YES:Switch is OK.
( 8 ) Auxiliary Hydraulic Override Switch (S21) Check
Action:
LEGEND:
2 Pin 2
3 Pin 3
Auxiliary Hydraulic Override Switch

Pins 2 and 3 in the OVERRIDE position.

Result:
YES:Switch is OK.

( 9 ) Quik-Tatch ™ Switch (S26) Check
Action:
LEGEND:
1 Pin 1
2 Pin 2
3 Pin 3
Quik-Tatch™ Switch
Pins 2 and 3 in the LOCK position.

Pins 1 and 2 in the UNLOCK position.
Result:
YES:Switch is OK.
( 10 ) Auxiliary Fourth Function Switch (S33) Check
Action:
LEGEND:
1 Pin 1
2 Pin 2
3 Pin 3
Auxiliary Fourth Function Switch

Pins 2 and 3 in the arrow left position.

Pins 1 and 2 in the arrow right position.
Result:
YES:Switch is OK.
( 11 ) Reversing Fan Switch (S35) Check
Action:
LEGEND:
2 Pin 2
3 Pin 3
5 Pin 5
6 Pin 6
Reversing Fan Switch

Pins 2 and 3 in the AUTO position.

Pins 5 and 6 in the PURGE position.
Result:
YES:Switch is OK.
( 12 ) Creep Mode Switch (S36) Check
Action:
LEGEND:
2 Pin 2
3 Pin 3
Creep Mode Switch


Result:
YES:Switch is OK.
( 13 ) Pattern Select Switch (S37) Check
Action:
LEGEND:
1 Pin 1
2 Pin 2
3 Pin 3
Pattern Select Switch

Pins 2 and 3 in the H position.

Pins 1 and 2 in the ISO position.
Result:
YES:Switch is OK.
( 14 ) Self Leveling Switch (S38) Check
Action:
LEGEND:
2 Pin 2
3 Pin 3
Self Leveling Switch


Result:
YES:Switch is OK.
( 15 ) Battery Voltage Check
Action:
Battery Voltage Check
Measure battery voltage by connecting a multimeter to negative (-) terminal grounded to frame and positive (+) terminal
connected to machine harness.
Is 12—14 volts measured?
Result:
YES:Battery is OK.
NO:Battery is undercharged. Charge battery.
( 16 ) Diode Check
Action:
Diode Check
Remove diode from connector.

Test diode using diode test function of multimeter.
Multimeter
To test diode.
Does multimeter beep?

Reverse multimeter probes.
Does multimeter beep?
Result:
YES:If multimeter beeps in both checks, diode has failed in a shorted mode. Replace diode.
NO:If multimeter does not beep in either check, diode has failed in an open mode. Replace diode.
NO:If multimeter beeps in one check and not the other, diode is OK.
( 17 ) Backup Alarm Check
Action:
LEGEND:
1 Backup Alarm
2 Terminal (+)
3 Terminal (-)
Backup Alarm
Connect jumper wire between terminal (2) and battery positive (+) terminal and connect terminal (3) to ground (-).
Does backup alarm sound?
Result:
YES:Backup alarm is OK.

NO:Backup alarm has failed. Replace. See Backup Alarm Remove and Install. (Group 9015-20.)
Electrical Component Specifications

Engine Sensors
Air Filter Restriction Switch (B1) Vacuum 64 mbar
4.8 cm of mercury
25.7 in of water
Fuel Level Sensor (B4) Resistance Empty tank 239.9 ohms
Half full tank 103.6 ohms
Full tank 32.4 ohms
First low fuel warning at 180 ohms
Second and third low fuel warning at 190 ohms
Engine Coolant Temperature Sensor (B5) Normal Operating Range 85°C—110°C
185°F—230°F
Full Operating Range -40°C— 125°C
-40°F— 257°F
STOP Indicator turns ON at 105°C
221°F
Engine Shutdown at 107°C or greater
225°F or greater
Voltage 4.732—4.762 volts at 0°C
4.378—4.407 volts at 20°C
1.315—1.344 volts at 100°C
4.732—4.762 volts at 32°F
4.378—4.407 volts at 68°F
1.315—1.344 volts at 212°F
Resistance 8800—10 000 ohms at 0°C
3300—3700 ohms at 20°C
172—183 ohms at 100°C
8800—10 000 ohms at 32°F
3300—3700 ohms at 68°F
172—183 ohms at 212°F
Engine Oil Pressure Switch (B6) (normally closed) Pressure 40—75 kPa
0.4—0.75 bar
5.8—10.8 psi
Engine Speed Control Dial (B18) Supply Voltage 4.5—5.5V
Output Voltage 0.5—4.5V
Operating Temperature -40°C— 125°F
-104°F— 257°F
Resistance 0.5—4.5 ohms
Fuel Pressure Sensor (B21) Resistance Terminals A—C 47 000 ohms
Crankshaft Speed Sensor (B22) Resistance Terminals A—B 2500—3500 ohms
Camshaft Speed Sensor (B23) Resistance Terminals A—B 2500—3500 ohms
Ambient Air Temperature Sensor (B24) Resistance 90 000—108 000 ohms at -40°C (-40°F)
26 000—31 000 ohms at -20°C (-4°F)
8700—10 200 ohms at 0°C (32°F)
3300—3800 ohms at 20°C (68°F)
1400—1600 ohms at 40°C (104°F)
648—708 ohms at 60°C (140°F)
317—350 ohms at 80°C (176°F)
170—186 ohms at 100°C (212°F)
97—105 ohms at 120°C (248°F)
Hydraulic Sensors
Hydraulic Oil Temperature Sensor (B2) Normal Operating Range 85°C—110°C
185°F—230°F
Full Operating Range -40°C— 125°C
-40°F— 257°F
STOP Indicator turns ON when 105°C or greater for 5 sec.
220°F or greater for 5 sec.
Engine Shutdown when STOP indicator ON for 5 min.
Voltage 4.732—4.762 volts at 0°C
4.378—4.407 volts at 20°C
1.315—1.344 volts at 100°C
4.732—4.762 volts at 32°F
4.378—4.407 volts at 68°F
1.315—1.344 volts at 212°F
Resistance 8800—10 000 ohms at 0°C
3300—3700 ohms at 20°C
172—183 ohms at 100°C
8800—10 000 ohms at 32°F
3300—3700 ohms at 68°F
172—183 ohms at 212°F
Hydraulic Oil Filter Restriction Switch (B3) Pressure Differential 248—303 kPa
2.5—3.0 bar
36—44 psi
Air Conditioning System Sensors

Air Conditioner High/Low Pressure Switch (B9) Closing Pressure—Low Side 160—260 kPa
1.6—2.6 bar
23—37 psi
Opening Pressure—Low Side 140—230 kPa
1.4—2.3 bar
20—33 psi
Opening Pressure—High Side 2600—2900 kPa
26.0—29.0 bar
380—420 psi
Closing Pressure—High Side 1380—2070 kPa
13.8—20.7 bar
200—300 psi
Air Conditioner Freeze Control Switch (B10) Temperature—Increasing -1.9— 0.8°C
29.5—32.5°F
Temperature—Decreasing 2.8—5.6°C
37—42°F
Solenoids
Park Brake Solenoid (Y5) Resistance 7—10.5 ohms
Boom Spool Lock Solenoid (Y2) Resistance 14.8—18.2 ohms
Bucket Spool Lock Solenoid (Y3) Resistance 14.8—18.2 ohms
Port Lock Solenoid (Y4) Resistance 8.2—9.0 ohms
High Flow Solenoid (Y7) Resistance 5.7—10.6 ohms
Two Speed Solenoid (Y6) Resistance 7—10.5 ohms
Right C1 Hydrostatic Pump Solenoid (Y15) Resistance 3.6—5.6 ohms
Right C2 Hydrostatic Pump Solenoid (Y16) Resistance 3.6—5.6 ohms
Left C2 Hydrostatic Pump Solenoid (Y17) Resistance 3.6—5.6 ohms
Left C1 Hydrostatic Pump Solenoid (Y18) Resistance 3.6—5.6 ohms
Boom Up Solenoid (Y19) Resistance 5.0—9.6 ohms
Boom Down Solenoid (Y20) Resistance 5.0—9.6 ohms
Bucket Curl Solenoid (Y21) Resistance 5.0—9.6 ohms
Bucket Dump Solenoid (Y22) Resistance 5.0—9.6 ohms
Auxiliary Port (male) Solenoid (Y23) Resistance 5.0—9.6 ohms
Auxiliary Port (female) Solenoid (Y24) Resistance 5.0—9.6 ohms
Hydraulic Fan Speed Solenoid (Y30) Resistance 6.0—8.2 ohms at 20°C (68°F)
Hydraulic Reversing Fan Solenoid A (Y31) Resistance 6.0—8.2 ohms at 20°C (68°F)
Hydraulic Reversing Fan Solenoid B (Y32) Resistance 6.0—8.2 ohms at 20°C (68°F)
Fan Bypass Solenoid (Y33) Resistance 6.0—8.2 ohms at 20°C (68°F)
Self Leveling Solenoid (Y38) Resistance 5.0—9.6 ohms
Speed Sensors
Left Wheel Speed Sensor (B16) Supply Voltage 4.5—5.5V
Operating Temperature -40°C—105°C
-104°F—221°F
Right Wheel Speed Sensor (B17) Supply Voltage 4.5—5.5V
Operating Temperature -40°C—105°C
-104°F—221°F
Relays
Starter Relay (K1) Resistance 70.38—86.02 ohms
Glow Plug Relay (K2) Resistance 63—77 ohms
Accessory Relay (K4) Resistance 70.38—86.02 ohms
Air Conditioner Compressor Clutch Relay (K7) Resistance 70.47—86.13 ohms
Ignition Relay (K8) Resistance 70.38—86.02 ohms
Quik-Tatch Relay (LOCK) (K13) Resistance 69.3—84.7 ohms
Quik-Tatch Relay (UNLOCK) (K14) Resistance 69.3—84.7 ohms
All Blower Motor Relays (K16-K19) Resistance 70.47—86.13 ohms
Solenoid Test
→NOTE:
When a component is disconnected from a harness, a diagnostic trouble code is triggered. Check and
clear codes after test is performed. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
Solenoid Observable Symptom Check

( 1 ) Boom Spool Lock and Bucket Spool Lock Solenoid (Y2 and Y3)
Action:
Perform boom and bucket spool lock solenoid test.

See Boom and Bucket Spool Lock Solenoid Test . (Group 9025-25.)
Do the pedals move and hydraulic functions operate?
Result:
YES:Boom spool lock and bucket spool lock solenoids are OK.
NO:Pedals or hand controls move and auxiliary hydraulics do not operate, check port lock solenoid (Y4).
NO:Pedals or hand controls do not move, continue check.
Action:
Switch boom spool lock and bucket spool lock solenoid with a known good solenoid.
Did the problem follow the boom spool lock and bucket spool lock solenoid?
Result:
YES:Solenoid has malfunctioned. Replace.

NO:Continue check.
Action:
Disconnect boom spool lock or bucket spool solenoid from harness.

Connect power to green wire and ground to black wire of boom spool lock or bucket spool lock solenoid.
→NOTE:
Boom spool or bucket spool lock solenoid makes a light click. Click is not audible in noisy conditions.
Does solenoid click?
Result:
YES:Solenoid is OK.
NO:Continue check.
Action:
Disconnect boom spool lock or bucket spool lock solenoid from harness.
Measure resistance across the terminals of boom spool lock or bucket spool lock solenoid.
Does solenoid resistance meet specification? See Electrical Component Specifications . (Group 9015-20.)
Result:
YES:Solenoid is OK.
NO:Solenoid has malfunctioned. Replace.

( 2 ) Port Lock Solenoid (Y4)
Action:
Perform port lock solenoid valve and port lock spool test.
See Port Lock Solenoid Valve and Port Lock Spool Test . (Group 9025-25.)
Do hydraulic functions operate?
Result:
YES:Port lock solenoid is OK.

NO:Pedals or hand controls move and auxiliary hydraulic functions do not operate, continue check.
NO:Pedals or hand controls do not move but auxiliary hydraulic functions operate, check boom and bucket spool lock solenoid.
Action:
Switch port lock solenoid with a known good solenoid.

Did the problem follow the port lock solenoid?
Result:

NO:Continue check.
Action:
Disconnect port lock solenoid from harness.

Connect power to green wire and ground to black wire of port lock solenoid.
→NOTE:
Port lock solenoid makes a light click. Click is not audible in noisy conditions.
Result:
YES:Solenoid is OK.
NO:Continue check.
Action:
Disconnect port lock solenoid from harness.

Measure resistance across terminals of port lock solenoid.
Result:
YES:Solenoid is OK.
( 3 ) Park Brake Solenoid (Y5)
Action:
Start machine and release park brake.

Push steering levers forward.
Does machine move?
Result:
YES:Park brake solenoid is OK.

NO:Continue check.
Action:
Perform park brake release pressure test.

See Park Brake Release Pressure Test . (Group 9026-25.)
Is park brake release pressure correct?
Result:
YES:Continue check.
NO:Correct park brake release pressure.
Action:
Switch park brake solenoid with a known good solenoid.

Did the problem follow the park brake solenoid?
Result:

NO:Continue check.
Action:
Disconnect park brake solenoid from harness.

Connect power to light blue wire and ground to black wire of park brake solenoid.
→NOTE:
Park brake solenoid makes a light click. Click is not audible in noisy conditions.
Result:
YES:Solenoid is OK.
NO:Continue check.
Action:
Disconnect park brake solenoid from harness.

Measure resistance across terminals of park brake solenoid.
Result:
YES:Solenoid is OK.
( 4 ) Two Speed Solenoid (Y6)
Action:
Drive machine and press two speed switch to activate two speed.
Does machine speed up?
Press two speed switch again while driving to deactivate two speed.
Does machine slow down?
Result:
YES:Two speed solenoid is OK.

NO:Continue check.
Action:
Switch two speed solenoid with a known good solenoid.

Did the problem follow the two speed solenoid?
Result:

NO:Continue check.
Action:
Disconnect two speed solenoid from harness.

Apply power to light blue wire and ground to black wire of two speed solenoid.
→NOTE:
Two speed solenoid makes a light click. Click is not audible in noisy conditions.
Result:
YES:Two speed solenoid is OK.

NO:Continue check.
Action:
Disconnect two speed solenoid from harness.

Measure resistance across solenoid terminals.
Result:
YES:Solenoid is OK.
( 5 ) High Flow Solenoid (Y7)
Action:
→NOTE:
Machine must be connected to a high flow attachment to perform this check.
Turn on high flow option and operate attachment.
Does attachment operate?
Result:
YES:Solenoid is OK.
NO:Continue check.
Action:
Switch high flow solenoid with a known good solenoid.

Did the problem follow the high flow solenoid?
Result:

NO:Continue check.
Action:
Disconnect high flow solenoid from harness.

Apply power to the dark green wire and ground the black wire of the high flow solenoid.
→NOTE:
High flow solenoid makes a light click. Click is not audible in noisy conditions.
Result:
YES:Solenoid is OK.
NO:Continue check.
Action:
Disconnect high flow solenoid from harness.

Result:
YES:Solenoid is OK.
( 6 ) Air Conditioning Compressor Clutch Solenoid (Y13)
Action:
Switch air conditioning compressor clutch solenoid with a known good solenoid.
Did the problem follow the air conditioning compressor clutch solenoid?
Result:

NO:Continue check.
Action:
Disconnect air conditioning compressor clutch solenoid from harness.

Result:
YES:Solenoid is OK.
( 7 ) Auxiliary Port (male) Solenoid (Y23)
Action:
IMPORTANT:
Avoid damage to solenoid. Do not apply power directly to solenoid to test. Direct power damages the
solenoid due to high amperage. Use EMU display or Service ADVISOR ™ to view voltage or current.
View solenoid current using the EMU, see Engagement and Monitor Unit Data Items . (Group 9015-16.)
→NOTE:
Start machine and enable hydraulics.

Operate the optional auxiliary hydraulic attachments.
Do attachments work?
Result:
YES:Auxiliary port (male) solenoid is OK.

NO:Continue check.
Action:
Switch auxiliary port (male) solenoid with a known good solenoid.

Did the problem follow the auxiliary port (male) solenoid?
Result:

NO:Continue check.
Action:
Disconnect auxiliary port (male) solenoid from harness.

Measure resistance across the terminals of auxiliary port (male) solenoid.
Result:
YES:Solenoid is OK.
( 8 ) Auxiliary Port (female) Solenoid (Y24)
Action:
IMPORTANT:
→NOTE:

Operate the optional auxiliary hydraulic attachments.
Do attachments work?
Result:
YES:Auxiliary port (female) solenoid is OK.

NO:Continue check.
Action:
Switch auxiliary port (female) solenoid with a known good solenoid.

Did the problem follow the auxiliary port (female) solenoid?
Result:

NO:Continue check.
Action:
Disconnect auxiliary port (female) solenoid from harness.

Measure resistance across the terminals of auxiliary port (female) solenoid.
Result:
YES:Solenoid is OK.
( 9 ) Hydraulic Fan Speed Solenoid (Y30)
Action:
IMPORTANT:
Switch hydraulic fan speed solenoid with a known good solenoid.

Did the problem follow the hydraulic fan speed solenoid?
Result:

NO:Continue check.
Action:
Disconnect hydraulic fan speed solenoid from harness.

Result:
YES:Solenoid is OK.
( 10 ) Hydraulic Reversing Fan Solenoid A (Y31)
Action:
Start machine and press reversing fan switch.

Does fan reverse?
Result:
YES:Solenoid is OK.
NO:Continue Check.
Action:
Switch hydraulic reversing fan solenoid A with a known good solenoid.

Did the problem follow the hydraulic reversing fan solenoid A?
Result:

NO:Continue check.
Action:
Disconnect hydraulic reversing fan solenoid A from harness.

Apply power to the white wire and ground the black wire of the hydraulic reversing fan solenoid A.
→NOTE:
Hydraulic reversing fan solenoid A makes a light click. Click is not audible in noisy conditions.
Result:
YES:Solenoid is OK.
NO:Continue check.
Action:
Disconnect hydraulic reversing fan solenoid A from harness.

Result:
YES:Solenoid is OK.
( 11 ) Hydraulic Reversing Fan Solenoid B (Y32)
Action:
Start machine and press reversing fan switch.

Does fan reverse?
Result:
YES:Solenoid is OK.
NO:Continue Check.
Action:
Switch hydraulic reversing fan solenoid B with a known good solenoid.

Did the problem follow the hydraulic reversing fan solenoid B?
Result:

NO:Continue check.
Action:
Disconnect hydraulic reversing fan solenoid B from harness.

Apply power to the white wire and ground the black wire of the hydraulic reversing fan solenoid B.
→NOTE:
Hydraulic reversing fan solenoid B makes a light click. Click is not audible in noisy conditions.
Result:
YES:Solenoid is OK.
NO:Continue check.
Action:
Disconnect hydraulic reversing fan solenoid B from harness.

Result:
YES:Solenoid is OK.
( 12 ) Fan Bypass Solenoid (Y33)
Action:
Switch fan bypass solenoid with a known good solenoid.

Did the problem follow the fan bypass solenoid?
Result:

NO:Continue check.
Action:
Disconnect fan bypass solenoid from harness.

Apply power to the white wire and ground the black wire of the fan bypass solenoid.
→NOTE:
Fan bypass solenoid makes a light click. Click is not audible in noisy conditions.
Result:
YES:Solenoid is OK.
NO:Continue check.
Action:
Disconnect fan bypass solenoid from harness.

Result:
YES:Solenoid is OK.
( 13 ) Self Leveling Solenoid (Y38)
Action:

Press self leveling switch to enable self leveling function.
Perform a boom up function.
Does bucket dump while boom is moving up?
Result:
YES:Solenoid is OK.
NO:Continue check.
Action:
Switch self leveling solenoid with a known good solenoid.

Did the problem follow the self leveling solenoid?
Result:

NO:Continue check.
Action:
Disconnect self leveling solenoid from harness.

Apply power to the dark green wire and ground the black wire of the self leveling solenoid.
→NOTE:
Self leveling solenoid makes a light click. Click is not audible in noisy conditions.
Result:
YES:Solenoid is OK.
NO:Continue check.
Action:
Disconnect self leveling solenoid from harness.

Result:
YES:Solenoid is OK.
Alternator Test
Common Alternator Circuit

LEGEND:
1 Battery
2 Alternator
3 Key Switch
4 To Accessories
5 ACC
6 Alternator Excitation Diode
7 Excitation Terminal (marked D+)
8 B+
9 Exciter Diodes
10 Positive Diodes
11 Negative Diodes
12 Stator
13 Excitation Winding (field)
14 Regulator
15 AC Terminal (marked W)
16 To Display Module (indicator lamp)
[1] - 12 V System — With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be
13.5 VDC or greater
[ Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage should be 14.1 VDC or greater. ]
.
[2] - With engine running at fast idle, check DC voltage between terminal B+ and ground. Voltage should be 13.5 VDC or
greater
.
[3] - If voltage from previous steps is below 13.5 VDC
, check excitation by placing a jumper wire between terminals D+ and B+ with the engine running. If output at terminals B+
and D+ rise to 13.5 VDC or greater, check for an open diode, wiring problem or blown fuse in the alternator excitation circuit
(wire to D+ terminal).
[4] - With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be 6—7 VAC .
[5] - Repeat above steps with lights on to load the alternator.

[6] - If alternator does not produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly.
Replace brush/regulator assembly if necessary. Test and repair if possible. If alternator still malfunctions, replace it. If
alternator tests OK, check indicator light circuit.
[1] - 24 V System — With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be
27.5 VDC or greater
.
[2] - With engine running at slow idle, check DC voltage between terminal B+ and ground. Voltage should be 27.5 VDC or
greater
.
[3] - If voltage from previous steps is below 27.5 VDC
, check excitation by placing a jumper wire between terminals D+ and B+ with the engine running. If output at terminals B+
and D+ rise to 27.5 VDC or greater, check for an open diode, wiring problem, or blown fuse in the alternator excitation circuit
(wire to D+ terminal).
[4] - With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be 12—14 VAC .
[5] - Repeat above steps with lights on to load the alternator.
[6] - If alternator does not produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly.
Replace brush/regulator assembly if necessary. Make specific test and repair procedures. If alternator still malfunctions,
replace it. If alternator tests OK, check indicator light circuit.
Controller Area Network (CAN) Circuit Test
Controller Area Network Circuit Schematic
LEGEND:
W2 Cab Harness
W3 Main Harness
W21 Starter Ground
Generic CAN Circuit Schematic

LEGEND:
1 Controller 1
2 Controller 2
3 Service ADVISOR™ Connector
4 Termination Resistor 1
5 Termination Resistor 2
6 CAN High Wire (yellow)
7 CAN Low Wire (light green)
8 Grounded Shield Wire (black)
For more information, See Controller Area Network (CAN) Theory of Operation . (Group 9015-15.)
Controller Area Network (CAN) Diagnostics

( 1 ) System Check
Action:
Turn ignition ON.

Locate the Service ADVISOR ™ connector and establish machine connection. See Service ADVISOR™ Connection Procedure .
(Group 9015-20.)
Does Service ADVISOR™ establish a connection?
Result:

NO:Go to Service ADVISOR™ Fuse Test.
Action:
Do all controllers show up under connected controllers?
Result:
YES:Go to CAN Termination Resistor Check.

Action:
Is Service ADVISOR able to connect to any machine controllers?
Result:
YES: Go to Controller Fuse Check .

NO: Go to CAN Circuit Short-to-Ground Check .
( 2 ) Service ADVISOR™ Fuse Test
Action:
Remove fuse for Service ADVISOR™ and check for continuity. For fuse location, See Fuse and Relay Specifications . (Group
9015-10.)
Result:
YES:Go to CAN Termination Resistor Check.

NO:Replace Service ADVISOR™ fuse.
( 3 ) CAN Termination Resistor Check
Action:
Turn ignition OFF. Locate, remove, and label each CAN termination resistor. Using a multimeter, measure the resistance of
each of the termination resistor (4 and 5).
Is resistance 110—130 ohms for each resistor?
Result:
YES:Go to CAN High Wire Voltage Check.

NO:Replace termination resistor.
( 4 ) CAN High Wire Voltage Check
Action:
Turn ignition ON. Using a multimeter, measure the voltage from pin C (CAN High) to pin A (ground) of Service ADVISOR
connector (3).
Is voltage between 2.50 and 3.50 volts?
Result:
YES:Go to CAN Low Wire Voltage Check.
Action:
Is system voltage present between pins C and A of Service ADVISOR connector?
Result:
YES:A short circuit exists on the CAN High wire. Check CAN High voltage one controller at a time to locate short circuit.
Action:
Is zero voltage present between pins C and A of Service ADVISOR connector?
Result:
YES: Go to CAN High Wire Circuit Check .

NO:Remove one controller at a time and recheck voltage. When voltage is in range, check harness of disconnected controller
for short circuits. Repair or replace harness as necessary.
( 5 ) CAN Low Wire Voltage Check
Action:
Using a multimeter, measure voltage from pin D (CAN Low) to pin A (ground) of Service ADVISOR connector.
Is voltage between 1.50 and 2.50 volts?
Result:
YES: Go to CAN High Wire Circuit Check .

Action:
Is system voltage present between pins D and A of Service ADVISOR connector?
Result:
YES:A short circuit exists on the CAN Low wire. Check CAN Low voltage one controller at a time to locate the short circuit.
Repair or replace harness as necessary.
Action:
Is zero voltage present between pins D and A of Service ADVISOR connector?
Result:
YES: Go to CAN Low Wire Circuit Check .

NO:Remove one controller at a time and recheck voltage. When voltage is in range, check harness of disconnected controller
for short circuits. Repair or replace harness as necessary.
( 6 ) CAN High Wire Circuit Check
Action:
Using a multimeter, measure continuity between pin C (CAN High) and pin A (ground) of Service ADVISOR connector.
Result:
YES:A short to ground exists on the CAN High wire. Check CAN High voltage one controller at a time to locate the harness
where the short is located. Repair or replace harness as necessary.
Action:
Using a multimeter, measure continuity between pin C (CAN High) and machine ground.
Result:
YES:A short to ground exists on the CAN High wire. Check CAN High voltage one controller at a time to locate the harness
where the short is located. Repair or replace harness as necessary.
NO:An open circuit exists on the CAN High wire. Repair or replace harness as necessary.
( 7 ) CAN Low Wire Circuit Check
Action:
Using a multimeter, measure continuity between pin D (CAN Low) and pin A (ground) of Service ADVISOR connector.
Result:
YES:A short to ground exists on the CAN Low wire. Check CAN Low voltage one controller at a time to locate the harness where
the short is located. Repair or replace harness as necessary.
Action:
Using a multimeter, measure continuity between pin D (CAN Low) and machine ground.
Result:
YES:A short to ground exists on the CAN Low wire. Check CAN Low voltage one controller at a time to locate the harness where
the short is located. Repair or replace harness as necessary.
NO:An open circuit exists on the CAN Low wire. Repair or replace harness as necessary.
( 8 ) CAN Circuit Short-to-Ground Check
Action:
Key switch OFF.

Using a multimeter, measure continuity between pin D (CAN Low) and pin A (ground) of Service ADVISOR connector.
Using a multimeter, measure continuity between pin C (CAN High) and pin A (ground) of Service ADVISOR connector.
Result:
YES:A short to ground exists in CAN circuit. Disconnect each harness and check for continuity to ground at pin A of Service
ADVISOR connector. Repair or replace harness that has short-to-ground condition.
Action:
Key switch OFF.

Using a multimeter, measure continuity between pin D (CAN Low) and machine ground.
Using a multimeter, measure continuity between pin C (CAN High) and machine ground.
Result:
YES:A short to machine ground exists in CAN circuit. Disconnect each harness and check for continuity to machine ground.
Repair or replace harness that has short-to-ground condition.
NO:Go to CAN High/CAN Low Short Check.
( 9 ) CAN High/CAN Low Short Check
Action:
Key switch OFF.

Using a multimeter, check for continuity between CAN High and CAN Low circuits.
Result:
YES:Short circuit between CAN High and CAN Low wires. Check continuity between CAN High and CAN Low circuits one
controller at a time to locate the harness where the short is located. Repair or replace harness as necessary.
NO: Go to Service ADVISOR™ Fuse Test .
( 10 ) Controller Fuse Check
Action:
Remove fuse for missing controller(s). Check fuse(s) for continuity.

Is continuity indicated in all fuses?
Result:
YES:Go to Controller Check.

NO:Replace fuse(s) that did not indicate continuity.
( 11 ) Controller Check
Action:
Key switch OFF.

Locate the suspected controller(s). Using a multimeter, measure resistance between the CAN High and CAN Low wires.
Is resistance between 55 and 65 ohms?
Result:

NO:An open or short circuit exists in one of the CAN wires. Work from the controller back to the main harness, checking the
CAN High and Low wires for an open or short circuit.
Action:
Turn ignition ON. Check for power and ground at suspect controller(s).
Is power and ground present?
Result:
YES:Replace malfunctioning controller.

NO:An open or short circuit exists in the circuit with no power or ground. Work from the controller back to the main harness,
checking the power and ground circuits for an open or short circuit. Repair or replace harness as necessary.
Auxiliary Hydraulics Calibration

This procedure calibrates the control valve threshold values for the auxiliary functions of the machine.
[1] -
→NOTE:
Calibration will quit if hydraulic oil temperature falls below operating temperature specification. Make
sure system oil is warm enough to maintain oil temperature during calibration procedure.
Operate machine to warm hydraulic system to operating temperature.

140°F
[2] - Remove front attachment and park machine on flat level surface.
[3] - Start engine and enable hydraulics.
[4] - If equipped with pattern select, place pattern select switch in ISO mode.
[5] - Operate engine at fast idle.

Engine Speed Fast Idle
[6] - Press and hold the MENU button on the engagement and monitor unit (EMU) for 5 seconds to access the service menu.
[7] - Press NEXT until MAIN MENU CALIBRATION displays. Press SELECT.
[8] - Press NEXT until CALIBRATION AUX HYDRAULICS displays.
[9] - Press SELECT. The display shows BEGINNING AUX THRESHOLD CAL.
→NOTE:
If any of the calibration preconditions are not met, the EMU displays a message:
ENGINE RPM TOO LOW FOR CAL
HYD OIL TEMP TOO LOW FOR CAL
MOVE ROLLER TO NEUTRAL (auxiliary proportional switch not in neutral)
[10] - If all calibration preconditions are met, the display shows AUX EXTEND UNTIL PRESSURE.
[11] -
→NOTE:
Press the MENU button to end the calibration procedure. At the prompt, press SELECT to end calibration
or BACK, NEXT, or MENU to resume calibration.
→NOTE:
If operator does not return auxiliary proportional switch to neutral immediately after the rise in pressure
is heard, AUX CALIBRATION FAILED will appear on the display for 2 seconds and the calibration procedure
will end. Normal runtime data appears on the screen and the previous calibration values are resumed.
Slowly move the auxiliary proportional switch forward until rise in pressure is heard. Return auxiliary proportional switch to
neutral.
The display shows AUX RETRACT UNTIL PRESSURE.
[12] - Slowly move the auxiliary proportional switch to rear until rise in pressure is heard. Return auxiliary proportional switch
to neutral.
[13] - Once the auxiliary thresholds have been calibrated, AUX CALIBRATION COMPLETE displays for 2 seconds before the EMU
returns to the normal runtime display.

If the calibration procedure does not complete correctly, AUX CALIBRATION FAILED displays on the EMU.
Engine Control Unit (ECU) Remove and Install

[1] - Park machine, raise and lock boom. See Boom Lock . (Operator′s Manual.)
[2] - Raise the operator′s station. See Raising Operator′s Station . (Operator′s Manual.)
[3] - Open engine cover. See Opening and Closing Engine Cover . (Operator′s Manual.)
[4] - Remove right side engine panel. See Engine Side Panels—Remove and Install . (Operator′s Manual.)
[5] -
IMPORTANT:
Prevent electrical component damage. Disconnecting the negative (-) battery cable will prevent voltage
spikes that can damage electrical components.
Disconnect negative (-) battery cable. See Handling, Checking, and Servicing Batteries Carefully . (Operator′s Manual.)
[6] -
LEGEND:
1 Cap Screw (2 used)
Engine Control Unit (ECU)

Disconnect electrical connectors (X15 and X16).
[7] - Remove cap screws (1) and engine control unit (ECU) (A3).
[8] - Inspect pins and sockets for damage or corrosion and repair as necessary.
[9] - Install ECU and cap screws.
[10] - Connect electrical connectors.
[11] - Lower operator′s station. See Raising Operator′s Station . (Operator′s Manual.)
[12] - Connect negative (-) battery cable. See Handling, Checking, and Servicing Batteries Carefully . (Operator′s Manual.)
[13] - Install right side engine panel. See Engine Side Panels—Remove and Install . (Operator′s Manual.)
[14] -
→NOTE:
If a new ECU was installed, it will be necessary to download the machine calibration from Service Advisor.
Connect Service ADVISOR ™ to the machine and download calibration. See Service ADVISOR™ Connection Procedure . (Group
9015-20.)
Engagement and Monitor Unit (EMU) Remove and Install

[2] - Raise boom and engage boom lock. See Boom Lock . (Operator′s Manual.)
[4] - Remove right side engine panel. See Engine Side Panels—Remove and Install . (Operator′s Manual.)
[5] -
IMPORTANT:
Disconnect negative (-) battery cable.
[6] -
LEGEND:
1 Bezel
2 Screw (2 used)
Engagement and Monitor Unit (EMU)

Remove screws (2), and lower engagement and monitor unit (EMU) (A2) and bezel (1).
[7] -
LEGEND:
1 Bezel
Engagement and Monitor Unit (EMU) 16-Pin Connector
X41
(J1)
X42
(J2)
X43
(J3)
Back of Engagement and Monitor Unit (EMU)

Disconnect electrical connectors (X41—X43) from EMU (A2).
[8] -
LEGEND:
1 Bezel
Engagement and Monitor Unit (EMU)

Remove cap screws (4) and EMU (A2) from bezel (1).
[9] - Install EMU into bezel, install cap screws.
[10] - Inspect all pins and sockets in connectors for corrosion or damage, replace as necessary.
[11] - Connect electrical connectors.
[12] - Install bezel with EMU to operator′s station and install screws.
[13] - Connect negative (-) battery cable.
[14] - Install right engine side panel. See Engine Side Panels—Remove and Install . (Operator′s Manual.)
[15] - Close engine cover. See Opening and Closing Engine Cover . (Operator′s Manual.)
[16] -
→NOTE:
When installing a new EMU, it is necessary to latest controller software for the machine to enable all
equipped options.
Connect Service ADVISOR ™ . See Service ADVISOR™ Connection Procedure . (Group 9015-20.)
[17] - Download the latest controller software for the machine.
[18] - Set the hour meter. See Engagement and Monitor Unit Initial Configuration . (Group 9015-16.)
Control Panel Remove and Install

[4] - Remove right engine side panel. See Engine Side Panels—Remove and Install . (Operator′s Manual.)
[5] -
IMPORTANT:
Disconnect negative (-) battery cable.
[6] -
LEGEND:
1 Screw (3 used)
2 Control Panel
Control Panel
Remove screws (1) and control panel (2).
[7] - Test or replace components as necessary.
[8] - Install control panel and screws.
[9] - Connect negative (-) battery cable.
[10] - Install right engine side panel. See Engine Side Panels—Remove and Install . (Operator′s Manual.)
[11] - Close engine cover. See Opening and Closing Engine Cover . (Operator′s Manual.)
[12] - Release boom lock and lower boom. See Boom Lock . (Operator′s Manual.)
Backup Alarm Remove and Install

[2] -
LEGEND:
2 Nut (2 used)
3 Nut (2 used)
4 Bracket
H2 Backup Alarm
Backup Alarm
Remove nuts (2) from cap screws (1).
[3] - Remove backup alarm (H2) from bracket (4).
[4] - Remove nuts (3) and wires from backup alarm.
[5] - Replace backup alarm as necessary.
[6] - Connect wires to backup alarm and install nuts.
[7] - Install backup alarm onto bracket.
[8] - Install cap screws and nuts securing backup alarm to bracket.
Battery Remove and Install

See Removing Battery . (Operator′s Manual.)
Replace (Pull Type) Metri-Pack™ Connectors

LEGEND:
A Connector
B “T” Pin
C Body Socket
D Locking Tab
E Push Terminal
Connector
Socket
Terminals
Disconnect the Metri-Pack

[ Metri-Pack is a trademark of Packard Electric ]
connector (A). Remove tie bands and tape.
Insert a “T” pin (B) 6.4 mm (1/4 in.) into connector body socket (C).
→NOTE:
Use JDG777
[ Included in JT07195A Electrical Repair Kit ]
Terminal Extraction Tool or “T” pin to remove terminals.
Angle “T” pin so pin tip slides close to the plastic socket edge pushing terminal locking tab (D) inward.
Remove “T” pin and push terminal (E) out of socket.
Remove terminal, cut strip and crimp wire through connector.
Check to make sure locking tab on new terminal is in outward position, then pull on wire until terminal locks in connector body
socket.
→NOTE:
Terminal will seat only one way. If terminal does not pull into the connector body socket, check to make
sure terminal is aligned correctly.
Replace (Push Type) Metri-Pack™ Connectors

LEGEND:
A Connector Lock
B Extraction Tool JDG777
C Connector Body Socket
D Terminal
E Locking Tab
Push Type Connector
Disconnect the Metri-Pack

[ Metri-Pack is a trademark of Packard Electric ]
connector. Remove the tie bands and tape.
Remove the connector lock (A), and mark wire colors for identification.
Identify wire color locations with connector terminal letters.
Insert JDG776 or JDG777
[ Included in JT07195A Electrical Repair Kit ]
Terminal Extraction Tool (B) into connector body socket (C) pushing the terminal locking tab inward.
→NOTE:
Use JDG776 Extraction Tool with 56, 280 and 630 series METRI-PACK terminals. Use JDG777 Extraction
Tool with 150 series METRI-PACK terminals.
Remove extraction tool and pull terminal (D) out of the socket.
Replace terminal. Make sure locking tab (E) on the new terminal is in the outward position.
Push terminal into connector body socket until terminal locks.
Replace Metri-Pack™ Connectors

LEGEND:
A Tab
B Screwdriver
Metri-Pack® Connector
[1] - A small locking tab (A) is located inside the Metri-Pack ™ connector. Use a small screwdriver (B) to move tab outward to
the first detent position; the tab will “click.”
[2] -
LEGEND:
A Wire
B Extractor Tool
JDG939 Metri-Pack® Extractor Tool

Slide JDG939 Metri-Pack® Extractor Tool (B) into connector body until it is positioned over terminal contact.
Metri-Pack® Extractor Tool
JDG939
JDG939 Metri-Pack® Extractor Tool
Used to extract Metri-Pack® terminals.
[3] - Pull wire out of connector body.
[4] -
IMPORTANT:
Install contact in proper location using correct size grommet.
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] -
LEGEND:
A Tab
B Screwdriver
Metri-Pack® Connector
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.
Replace WEATHER PACK ™ Connector
Terminal Contact
IMPORTANT:
Identify wire color locations with connector terminal letters.
[1] - Open connector body.
[2] - Insert JDG364 Extraction Tool over terminal contact in connector body.
[3] - Hold extractor tool fully seated and pull wire from connector body.
→NOTE:
If terminal cannot be removed, insert wire or nail through extractor tool handle and push terminal
contact from connector.
[4] -
IMPORTANT:
Connector Body
Carefully spread contact lances to assure good seating on connector body.
→NOTE:
Connector bodies are "keyed" for proper contact mating. Be sure contacts are in proper alignment.
Push contact into new connector body until fully seated.
[7] - Close connector body.
Install WEATHER PACK ™ Contact
Correct Size Cable
Strip Insulation
→NOTE:
Cable seals are color coded for three sizes of wire:
Green - 18 to 20 gauge wire

Gray - 14 to 16 gauge wire
Blue - 10 to 12 gauge wire
[1] - Slip correct size cable seal on wire.
[2] - Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation.
[3] -
→NOTE:
Contacts have numbered identification for two sizes of wire: a) #15 for 14 to 16 gauge wire b) #19 for 18
to 20 gauge wire
Put proper size contact on wire and crimp in place with a "W" type crimp, using JDG783 Terminal Applicator.
[4] -
IMPORTANT:
Contact Installation
Proper contact installation for "sleeve" (A) and "pin” (B) is shown.
Secure cable seal to contact as shown, using JDG783 Terminal Applicator.
Replace DEUTSCH ™ Rectangular or Triangular Connectors

[1] -
→NOTE:
Connector shown is the female half or a 4-pin square connector. Other similar styles of Deutsch
connectors can be serviced using the same procedure.
LEGEND:
1 Connector
2 Locking Wedge
Removing Locking Wedge

Pull connector (1) apart. Inspect and clean connector seal and contacts.
[2] - Remove locking wedge (2) from connector using hook on JDG1383 service tool.
DEUTSCH ™ Connector Service Tool
JDG1383
Remove secondary contact lock.
[3] -
LEGEND:
3 Primary Locking Latches
Releasing Primary Latch
Removing Wire
Release primary locking latch (3) next to the pin to be removed using screwdriver on JDG1383 service tool.
[4] - Gently pull wire out from back of connector.
[5] - Replace connector contact as necessary.
[6] - Install wire terminal back into connector until it clicks into place.
[7] -
→NOTE:
Locking wedge in 2-pin connector is not symmetrical. Position latch shoulder next to terminals.
Install locking wedge until it snaps into place.
Replace DEUTSCH ™ Circular Connectors

[1] -
→NOTE:
JDG361 Extractor Tool, JDG362 Extractor Tool, and JDG363 Extractor Tool are available in JDG359
DEUTSCH ™ Electrical Repair Tool Kit.
Select correct size extractor tool for size of wire to be removed:

DEUTSCH® Electrical Repair Tool Kit
JDG359
JDG359 Electrical Repair Tool Kit
To repair DEUTSCH® electrical connectors.
JDG361 Extractor Tool for 12 to 14 gauge wire.

JDG363 Extractor Tool for 20 gauge wire.
[2] -
LEGEND:
A Extractor Tool
Extractor Tool
Slide Extractor Tool

Start correct size extractor tool (a) over wire at handle.
[3] - Slide extractor tool along wire until tool tip snaps onto wire.
[4] -
IMPORTANT:
Avoid connector damage. Do not twist tool when inserting in connector.
Slide extractor tool along wire into DEUTSCH® connector body until it is positioned over terminal contact.
[5] - Pull wire out of connector body using extractor tool (A).
[6] -
IMPORTANT:
Avoid electrical malfunction. Install contact in proper connector location using correct size grommet.
Push Contact
[7] - Pull on wire and verify contact is locked in place.
Replace DEUTSCH ™ Connectors
Extractor Tool
Slide Extractor Tool
[1] - Select correct size extractor tool for size of wire to be removed:

JDG363 Extractor Tool for 20 gauge wire.
[2] - Start correct size extractor tool over wire at handle (A).
[3] - Slide extractor tool rearward along wire until tool tip snaps onto wire.
[4] -
IMPORTANT:
Do NOT twist tool when inserting in connector.
Slide extractor tool along wire into connector body until it is positioned over terminal contact.
[5] - Pull wire out of connector body, using extractor tool.
[6] -
IMPORTANT:
Install contact in proper location using correct size grommet.
Push Contact
Install DEUTSCH ™ Contact
Crimper
[1] - Strip 6 mm (1/4 in.) insulation from wire.
[2] - Adjust selector (A) on JDG360 Crimper for correct wire size.
[3] - Loosen lock nut (B) and turn adjusting screw (C) in until it stops.
[4] -
IMPORTANT:
Select proper size contact "sleeve" or "pin" to fit connector body.
Adjusting Screw
Insert contact (A) and turn adjusting screw (D) until contact is flush with cover (B).
[5] - Tighten lock nut (C).
[6] -
IMPORTANT:
Contact must remain centered between indentors while crimping.
Crimp
Insert wire in contact and crimp until handle touches stop.
[7] - Release handle and remove contact.
[8] -
IMPORTANT:
If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation
procedures.
→NOTE:
Readjust crimping tool for each crimping procedure.
Inspect Contact
Inspect contact to be certain all wires are in crimped barrel.
Replace CINCH™ Connectors

[1] -
LEGEND:
1 Extraction Tool
2 Secondary Lock Locking Tabs
3 Secondary Lock
Unlock Secondary Lock

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 CINCH ™ 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 screwdriver or similar device may be used to hold it in
the unlocked position while unlocking the second locking tab.
[3] -
LEGEND:
3 Secondary Lock
Remove Secondary Lock

Remove secondary lock (3).
[4] -
LEGEND:
1 Extraction Tool
4 Cavity
Removing Terminals
Insert pointed side of extraction tool (1) 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] - Pull wire out of the connector.
[6] - Replace terminals as necessary. See Install CINCH™ Contact . (Group 9015-20.)
[7] - Insert contact and wire into connector until it clicks.
[8] - Install secondary lock.
Install CINCH™ Contact

[1] -
Tool Position For Insertion

LEGEND:
A Top of Tool
B Contact Support
C Locator
D Wire
E Micro Timer Slot
F Junior Timer Slot
G Contact
I Wire Tab
J Insulation Tab
Hold JDG708 AMP ™ Crimper so that the tool is facing you as shown (left side of graphic). Squeeze crimper handles together
and allow them to open fully.
AMP® Crimper
JDG708
Install CINCH™ contacts.
[2] -
IMPORTANT:
Make sure that both sides of the insulation barrel are started evenly into the crimping section. Do not
attempt to crimp an improperly positioned contact.
Position the CINCH ™ contact so that the mating end of the contact (G) is on the locator side of the tool (C). Wire and insulation
tabs (I and J) should point to top of tool (A). Push wire tab (I) against the movable locator (C).
[3] - Hold the contact in position and squeeze crimper handles together until ratchet engages sufficiently to hold the contact in
position. Do not deform wire and insulation tabs (I and J).
[4] - Insert stripped wire into contact insulation and wire tabs until it is against locator (C).
[5] - Hold the wire in place. Squeeze crimper handles together until ratchet releases. Allow crimper handles to open and
remove crimped contact.
[6] - Install contact into connector. See Replace CINCH™ Connectors . (Group 9015-20.)
Repair 32 and 48 Way CINCH™ Connectors

[1] -
LEGEND:
A Tab
B Locking Cam
C Cover Locks
D Cover
CINCH ™ Connector
CINCH™ Cover Lock Tabs
CINCH™ Cover
Push tab (A) and rotate locking cam (B) 90° to disconnect connector from controller.
[2] - Move cover locks (C) slightly outward with a small screwdriver.
[3] - Remove cover (D) away from wires.
[4] -
LEGEND:
A Terminal Lock
Terminal Lock
Pull terminal lock (A) out until it stops. Do not force its removal.
[5] -
→NOTE:
JDG1725 Terminal Extractor Tool is included in JDG1725 Flexbox Terminal Repair Kit.
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).
LEGEND:
A 20 Gauge Holes
B 16 and 18 Gauge Holes
C Holes
D Terminal Hole
E Terminal
Connector Holes
CINCH Connector Terminal Holes
CINCH Terminal Extraction Tool

Insert JDG1725 Terminal Extractor Tool into holes (C) next to terminal opening (D) to unlock terminal.
Flexbox Terminal Repair Kit
JDG1744
JDG1744
Repair CINCH™ wire connectors
[6] - Pull wire and terminal (E) from connector body.
[7] -
LEGEND:
A CINCH™ Terminal Crimping Tool
B Terminal Receptacle
C Terminal
D Wire
Crimp Terminal
CINCH™ Terminal Crimping Tool
Terminal Crimping Tool

Remove old terminal and strip 4.85 mm (0.191 in.) of insulation from wire.
POWER TRAIN (g) by Belgreen v2.0
[8] -
→NOTE:
JDG1727 Terminal Crimping Tool is included in JDG1725 Flexbox Terminal Repair Kit.
Firmly grip JDG1727 Terminal Crimping Tool (A). Squeeze ratcheting mechanism until it bottoms out, then allow it to open
completely.
[9] - With tool in ready position (open handle), open terminal receptacle (B).
[10] - Insert terminal (C) into correct wire gauge window so crimp wings are facing up.
[11] - Close terminal receptacle (B).
[12] - Squeeze handle until two clicks are heard.
[13] - Insert stripped wire (D) into terminal.
[14] - Hold wire stationary and squeeze tool together until ratchet releases.
[15] - Remove terminated wire from tool.
[16] - Push terminal into connector body until fully seated. Pull on wire slightly to ensure terminal is locked in position.
[17] - Push terminal lock closed.
[18] - Install cover.
[19] - Install connector to controller and close connector body locking cam.
Remove Connector Body from Blade Terminals
Blade Terminals
[1] - Depress locking tang (A) on terminal, using a small screw driver. Slide connector body off.
[2] - Be sure to bend locking tang back to its original position (B) before installing connector body.
Section 9020 - POWER TRAIN

Table of contents
Power Train System Operation ............................................................................................................. 1
Hydrostatic Motor Gearbox Operation (S.N. —192141) ........................................................................ 2
Hydrostatic Motor Gearbox Operation (S.N. 192142— ) ....................................................................... 3
Track Adjuster and Recoil Spring Operation ......................................................................................... 4
Power Train Component Location ......................................................................................................... 5
Loose Track Diagnostic Procedure ........................................................................................................ 9
Tight Track Diagnostic Procedure ......................................................................................................... 9
Frequent Track Tension Adjustment Diagnostic Procedure ................................................................ 10
Excessive Oil Leakage From Idlers And Rollers Diagnostic Procedure ................................................ 10
‘Popping” Of Track Diagnostic Procedure ........................................................................................... 10
Individual Undercarriage Component Wear Diagnostic Procedure ..................................................... 11
Group 25 - Tests ..................................................................................................................................... 12
Check and Adjust Track Tension ......................................................................................................... 12

Section 9020 - POWER TRAIN Group 05: Theory of Operation

Power Train System Operation
The compact track loader power train transmits power from the hydrostatic motor through the hydrostatic motor gearbox to
the drive sprocket and tracks. The hydrostatic motor is mounted on the park brake assembly, which is attached to the
undercarriage support on the outside of the machine frame. The motor is splined to the park brake drive shaft. The drive shaft
is also splined to the hydrostatic motor gearbox, which reduces shaft speed and increases torque transmitted to the drive
sprocket and tracks. The left and right power trains are separate units. The drive system is the same for forward and reverse;
the drive motor is reversed through the hydrostatic system.
Hydrostatic Motor Gearbox Operation (S.N. —192141)
Hydrostatic Motor Gearbox Component Location (two speed motor shown)

LEGEND:
2 Left Hydrostatic Motor Park Brake
4 Left Hydrostatic Two Speed Motor (if equipped)
125 Hydrostatic Motor Gearbox
126 Park Brake Drive Shaft
127 Sun Gear
128 Planet Gear (4 used)
129 Ring Gear
130 Housing Drum
186 Drive Sprocket
The hydrostatic motor gearbox (125) is a single reduction planetary drive. The function of the motor gearbox is to convert fast
rotary speed and low torque from the hydrostatic motor to a slow rotary speed and high torque to rotate the drive sprocket
(186).
Rotary motion is transferred from the park brake drive shaft (126) to the drive sprocket by a single planetary gear set that
meshes with the ring gear (129). As the park brake drive shaft turns, the splined sun gear (127) turns against the planet gears
(128). Because the planet gear carrier is fixed to the park brake housing and does not rotate, the rotation of the planet gears is
transferred to and turns the ring gear. The ring gear, housing drum (130) and drive sprocket all turn as a unit driving the track
to move the machine.
Hydrostatic Motor Gearbox Operation (S.N. 192142— )
Hydrostatic Motor Gearbox Component Location (S.N. 192142— )

LEGEND:
1 End Cover
2 Snap Ring
3 Thrust Washer
4 Input Shaft
5 Input Carrier Assembly
6 Thrust Washer
7 Output Carrier Assembly
8 Lock Nut
9 Bearing (2 used)
10 Metal Face Seal (2 used)
11 Gearbox Housing
12 Plug (3 used)
13 Park Brake ( see Park Brake System Operation ) (Group 9026-05.)
14 Hydrostatic Motor ( see Hydrostatic Motor Operation (S.N. 192142— ) ) (Group 9026-05.)
The hydrostatic motor gearbox converts fast rotary speed and low torque from the hydrostatic motor to a slow rotary speed
and high torque to rotate the drive sprocket, which is mounted to the gearbox housing (11).
Rotary motion from the hydrostatic motor is first transferred from the input shaft (4) to the planet gears in the input carrier
assembly (5). As the planet gears in the input carrier assembly rotate, they turn the sun gear in the output carrier assembly.
The sun gear in the output carrier assembly drives the planet gears in the assembly, which rotate the ring gear attached to the
gearbox housing. The ring gear, gearbox housing drum, and drive sprocket all turn as a unit to drive the track to move the
machine.
Section 9020 - POWER TRAIN Group 15: Diagnostic Information
Track Adjuster and Recoil Spring Operation
Track Adjuster and Recoil Spring Component Location

LEGEND:
187 Idler
188 Roller
191 Undercarriage Frame
192 Grease Fitting
193 Adjuster Valve
194 Recoil Spring
195 Piston
196 Yoke
The track adjuster and recoil spring assembly is supported by the undercarriage frame (191). Shock loads on idler (187) and
roller (188) are absorbed by the recoil spring (194).
To tighten the track, pump grease into fitting (192) to force the piston (195) out. As it presses against the yoke (196), the track
becomes tighter. Loosen adjuster valve (193), NOT the grease fitting (192) to release grease to loosen the track. Grease will
escape through a small passage that is concealed by the adjuster valve. For more information, see Check and Adjust Track
Tension . (Group 9020-25.)

Power Train Component Location
Power Train Component Location—329D Single Speed (S.N. —192141 shown)
LEGEND:
3 Left Hydrostatic Motor
11 Hydrostatic Control Valve
14 Right Hydrostatic Motor Park Brake
15 Right Hydrostatic Motor
27 Left Hydrostatic Pump
35 Right Hydrostatic Pump
44 Hydraulic Pump
46 Charge Pump
186 Drive Sprocket (2 used)
187 Idler (4 used)
188 Roller (8 used)
189 Track Adjuster and Recoil Spring Assembly (2 used)
190 Track (2 used)
191 Undercarriage Frame (2 used)
197 Hydrostatic Motor Gearbox (2 used)
Power Train Component Location—329D, 333D Two Speed (S.N. —192141 shown)
LEGEND:
4 Left Hydrostatic Two Speed Motor
16 Right Hydrostatic Two Speed Motor
44 Hydraulic Pump
46 Charge Pump
186 Drive Sprocket (2 used)
187 Idler (4 used)
188 Roller (8 used)
189 Track Adjuster and Recoil Spring Assembly (2 used)
190 Track (2 used)
191 Undercarriage Frame (2 used)
Loose Track
81
Loose Track Diagnostic Procedure

( 1 ) Incorrect Track Tension Adjustment
Action:
Check track tension. See Check and Adjust Track Tension . (Group 9020-25.)
Is track tension incorrect?
Result:
YES: Perform Check and Adjust Track Tension . (Group 9020-25.)

NO:Go to Grease Leaking From Track Adjuster Seals, Grease Fitting, or Valve.
( 2 ) Grease Leaking From Track Adjuster Seals, Grease Fitting, or Valve
Action:
Is grease leaking from track adjuster seals, grease fitting, or valve?
Result:
YES: See Track Adjuster Cylinder Disassemble and Assemble . (Group 0130.)
NO:Done.
Tight Track
81
Tight Track Diagnostic Procedure

( 1 ) Material Packing in Sprocket
Action:
Check sprocket.
Is there material filling drive sprocket teeth?
Result:
YES:Remove foreign material from drive sprocket teeth and perform Check and Adjust Track Tension . (Group 9020-25.)
NO:Go to Track Tension Less Than Specification.
( 2 ) Track Tension Less Than Specification
Action:
Check track tension. See Check and Adjust Track Tension . (Group 9020-25.)
Is track tension incorrect?
Result:
YES: Perform Check and Adjust Track Tension . (Group 9020-25.)

NO:Done.
Frequent Track Tension Adjustment Required
81
Frequent Track Tension Adjustment Diagnostic Procedure

( 1 ) Grease Leaking From Track Adjuster Seals, Grease Fitting, or Valve
Action:
Is grease leaking from track adjuster seals, grease fitting, or valve?
Result:
YES: See Track Adjuster Cylinder Disassemble and Assemble . (Group 0130.)
NO:Done.
Excessive Oil Leakage From Idlers And Rollers
81
Excessive Oil Leakage From Idlers And Rollers Diagnostic Procedure

( 1 ) Loose Plug, Worn Or Damaged O-Ring, Or Metal Faced Seal
Action:
Check plugs, O-ring, or metal faced seals on front idlers and rollers.
Are plugs loose? Are O-rings or metal faced seals damaged?
Result:
YES: See Front or Rear Idler Disassemble and Assemble and see Track Roller Disassemble and Assemble . (Group 0130.)
NO:Done.
“Popping” Of Track
81
“Popping” Of Track Diagnostic Procedure

( 1 ) High Propel Loads In Reverse
Action:
High propel loads in reverse can cause the recoil spring to retract allowing sprocket to slip in track. Is track “popping” with high
propel loads in reverse?
Result:
YES:Lighten load.
NO:Go to Material Packing in Sprocket.
( 2 ) Material Packing in Sprocket
Action:
Check sprocket.
Is there material filling drive sprocket teeth?
Section 9020 - POWER TRAIN Group 25: Tests
Result:
YES:Remove foreign material from drive sprocket teeth and perform Check and Adjust Track Tension . (Group 9020-25.)
NO:Done.
Individual Undercarriage Component Wear
81
Individual Undercarriage Component Wear Diagnostic Procedure

( 1 ) Normal Component Wear
Action:
Inspect undercarriage components. Some wear is normal.

Do components need to be replaced?
Result:
YES:For undercarriage component repair information, see Track System. (Group 0130.)
NO:Done.
Group 25 - Tests
Check and Adjust Track Tension
Specifications
SPECIFICATIONS
13—25 mm
Track Sag (S.N. —192141)
0.5—1.0 in.
25—38 mm
Track Sag (S.N. 192142— )
1.0—1.5 in.
Grease Gun
Other Material
OTHER MATERIAL
Multi-Purpose Grease
This test checks track tension by measuring the amount of track sag.
[1] -
IMPORTANT:
Test can only be performed safely and accurately by using a bucket to raise machine to proper height. DO
NOT use a broken or worn out bucket when checking or adjusting track tension.
→NOTE:
Track tension can also be checked and adjusted by safely blocking the machine in the air, such as when
performing track component repair or replacement. See Raising and Blocking Machine . (Operator′s
Manual.)
Install bucket attachment on machine.
[2] - Park machine on a hard, flat level surface.
[3] - Lower boom completely until it rests on stops.
[4] - Dump bucket to raise front end of tracks approximately 200 mm (8 in.).
[5] - Apply the park brake.
[6] - Turn the key switch to the OFF position.
[7] -
CAUTION:
Prevent injury due to unexpected machine movement during servicing. Be alert to possible machine
movement caused by hydraulic leakage. If the hydraulics drift then the machine should be blocked into
the air to check track sag.
From the seat, verify the machine is stable and the front end is still raised.
[8] -
CAUTION:
Avoid possible injury from falls or slips. Use care when entering and exiting machine with front end
raised. Maintain three point contact. DO NOT use bucket as foothold when machine is in raised position.
Exit machine using handholds (4) and top of track (3) for assistance.
LEGEND:
3 Step Point (2 each)
4 Handhold (2 each)
Exit and Entry Points
[9] -
→NOTE:
If gravel or mud is packed between sprocket and track, it must be removed before adjusting track.
Measure track sag at bottom of third roller (from rear of machine) to top of track. Bottom of roller should not be touching track.
Track Sag (S.N. —192141) 13—25 mm
0.5—1.0 in.
Track Sag (S.N. 192142— ) 25—38 mm
1.0—1.5 in.
[10] -
LEGEND:
1 Grease Fitting
2 Adjuster Valve
Track Adjuster
If track sag is not within specification, remove track adjuster cover plate on track frame.
[11] -
HYDRAULIC SYSTEM (g) by Belgreen v2.0
CAUTION:
Prevent personal injury from high pressure grease in track adjuster cylinder. Do not loosen track
adjuster valve (2) quickly or too much. Never loosen grease fitting (1) to release grease.
IMPORTANT:
Prevent possible damage to track components. Do not use the grease fitting on track adjuster cylinder
for lubrication. Use grease fitting only for track sag adjustment.
To decrease track sag, add grease to track adjuster cylinder through grease fitting (1). This decreases track sag by increasing
track tension.
To increase track sag, loosen track adjuster valve (2) 1—2 turns to release grease from track adjuster cylinder. This increases
track sag by decreasing track tension.
Tighten track adjuster valve when track sag is correct.
Track Sag (S.N. —192141) 13—25 mm
0.5—1.0 in.
Track Sag (S.N. 192142— ) 25—38 mm
1.0—1.5 in.
Grease Gun
Used for decreasing track sag.
Number Name Use

Multi-Purpose Grease Used for decreasing track sag.
[12] - Install track adjuster cover plate on track frame.
[13] - Repeat procedure for other track.
[14] -
CAUTION:
Avoid possible injury from falls or slips. Use care when entering and exiting machine with front end
raised. Maintain three point contact. DO NOT use bucket as foothold when machine is in raised position.
Enter machine using top of track and handholds on machine for assistance.
[15] - Start machine and rollback bucket to lower front end.
Section 9025 - HYDRAULIC SYSTEM

Table of contents
Hydraulic System Operation ................................................................................................................. 1
Hydraulic Oil Filter Manifold Operation ................................................................................................. 2
High Flow Pump Operation—If Equipped .............................................................................................. 3
Self Leveling Valve Operation—If Equipped .......................................................................................... 5
Hydraulic Pump Operation .................................................................................................................... 7
Hydraulic Fan Operation ....................................................................................................................... 9
Hydraulic Control Valve Operation ..................................................................................................... 15
Group 15 - Diagnostic Information ...................................................................................................... 20
Hydraulic System Schematic .............................................................................................................. 20
Hydraulic System Component Location .............................................................................................. 25
Diagnose Hydraulic System Malfunctions ........................................................................................... 26
No Hydraulic Functions Diagnostic Procedure .................................................................................... 27
Boom Will Not Raise Diagnostic Procedure ......................................................................................... 29
Boom Will Not Lower Diagnostic Procedure ........................................................................................ 32
Bucket Will Not Dump Diagnostic Procedure ...................................................................................... 35
Bucket Will Not Curl Diagnostic Procedure ......................................................................................... 37
Bucket Will Not Self Level When Boom is Raised Diagnostic Procedure ............................................. 39
Bucket Dumps During Self Leveling Cycle Diagnostic Procedure ....................................................... 40
Boom Drifts Down Diagnostic Procedure ............................................................................................ 41
Boom Drifts Up Diagnostic Procedure ................................................................................................. 43
Bucket Drifts Down Diagnostic Procedure .......................................................................................... 45
Bucket Drifts Up Diagnostic Procedure ............................................................................................... 47
Hydraulic Functions Slow or No Power Diagnostic Procedure ............................................................. 49
Hydraulic Functions ‘Jerky” or ‘Spongy” Diagnostic Procedure .......................................................... 52
Hydraulic System Noise Diagnostic Procedure ................................................................................... 55
Pedals Will Not Move Diagnostic Procedure ........................................................................................ 57
Hydraulic Oil Overheats Diagnostic Procedure ................................................................................... 58
Hydraulic Fan System Malfunctions Diagnostic Procedure ................................................................. 61
Hydraulic Fan Will Not Reverse Direction Diagnostic Procedure ......................................................... 64
Group 25 - Tests ..................................................................................................................................... 65
JT05800 Digital Thermometer Installation .......................................................................................... 65
JT02156A Digital Pressure/Temperature Analyzer Installation ............................................................ 66
Remote Start Box Installation ............................................................................................................. 68
Hydraulic System Pressure Release ................................................................................................... 70
Boom Release Cable Adjustment ........................................................................................................ 72
Pilot Control Accumulator Precharge Test .......................................................................................... 73
Port Lock Solenoid Valve and Port Lock Spool Test ............................................................................ 75
Boom and Bucket Spool Lock Solenoid Test ....................................................................................... 75
Hydraulic System Relief Valve Test .................................................................................................... 77
Charge Pressure Relief Valve Test ...................................................................................................... 80
Circuit Relief Valve Test ...................................................................................................................... 82
Function Drift Test .............................................................................................................................. 90
Hydraulic Cylinder Leakage Test ........................................................................................................ 95
Hydraulic Pump Flow Test .................................................................................................................. 97
Charge Pump Flow Test .................................................................................................................... 102
Hydraulic Fan Motor Speed Test ....................................................................................................... 104
Hydraulic Fan Motor Case Drain Test ............................................................................................... 109
Fan Bypass Valve Test ...................................................................................................................... 111

Section 9025 - HYDRAULIC SYSTEM Group 05: Theory of Operation

Hydraulic System Operation
The hydraulic system provides fluid power to charge the hydrostatic system and to operate the boom and bucket cylinders and
auxiliary hydraulic attachments. The hydraulic system generates hydraulic oil pressure with two separate pumps. Both pumps
draw hydraulic oil from the hydraulic oil tank. For more information, see Hydraulic Pump Operation (Group 9025-05) and see
Charge Pump Operation . (Group 9026-05.)
The hydraulic pump supplies oil at supply oil pressure to the hydraulic control valve. For more information, see Hydraulic
Control Valve Operation . (Group 9025-05.)
The charge pump supplies oil at charge oil pressure to the hydraulic fan system and hydraulic oil filter manifold. For more
information, see Hydraulic Fan Operation and see Hydraulic Oil Filter Manifold Operation . (Group 9025-05.) The charge pump
also supplies charge oil to the hydrostatic system and the hydraulic control valve. For more information, see Hydrostatic
System Operation (Group 9026-05) and see Hydraulic Control Valve Operation . (Group 9025-05.)
The pilot control accumulator manifold ensures that there is pilot oil available to release the hydraulic oil pressure in the
hydraulic system when no engine power is available. A hydraulic oil cooler bypass valve is available to bypass the hydraulic oil
cooler when the hydraulic oil flow through the cooler is restricted due to cold oil or a dirty or plugged hydraulic oil cooler.
If equipped, the self leveling valve ensures that the bucket stays level during the entire boom cycle. For more information, see
Self Leveling Valve Operation—If Equipped . (Group 9025-05.)
If equipped, the high flow pump supplies high flow hydraulic oil to the high flow auxiliary ports. For more information, see High
Flow Pump Operation—If Equipped . (Group 9025-05.)
For more information, see Hydraulic System Schematic and see Hydraulic System Component Location . (Group 9025-15.)
Hydraulic Oil Filter Manifold Operation
Hydraulic Oil Filter Manifold

LEGEND:
47 Hydraulic Oil Filter Manifold
48 Hydraulic Oil Filter Bypass Valve
49 Hydraulic Oil Filter
50 Hydraulic Oil Test Port
200 Charge Oil from Hydraulic Fan System
201 Charge Oil to Hydraulic and Hydrostatic Systems
611 Charge Pressure Oil
The hydraulic oil filter manifold (47) contains the hydraulic oil filter (49), hydraulic oil filter restriction switch (B3) and hydraulic
oil filter bypass valve (48). The hydraulic oil filter manifold is located behind the right rear access door. See Hydraulic System
Charge pressure oil (611) from the hydraulic fan system (200) flows to the hydraulic oil filter, hydraulic oil filter bypass valve,
and hydraulic oil filter restriction switch. The hydraulic oil filter is a canister-type, screw-on filter. Charge pressure oil flows
through the hydraulic oil filter to the hydraulic and hydrostatic systems (201).
If charge pressure oil at the hydraulic oil filter rises above a specified value, the hydraulic oil filter restriction switch closes. A
signal is sent to the engagement and monitor unit. The engagement and monitor unit indicates a plugged hydraulic oil filter.
See Engagement and Monitor Unit (EMU) Circuit Theory of Operation . (Group 9015-15.) If the pressure differential at the
hydraulic oil filter continues to rise above the specified value, the hydraulic oil filter bypass valve opens. Unfiltered hydraulic oil
flows to the hydraulic and hydrostatic systems.
For more information, see Hydraulic System Schematic . (Group 9025-15.)
High Flow Pump Operation—If Equipped
High Flow Pump

LEGEND:
62 High Flow Valve (if equipped)
63 High Flow Spool (if equipped)
64 High Flow Relief Valve (if equipped)
65 High Flow Pump Housing (if equipped)
66 High Flow Pump (if equipped)
67 Hydraulic Oil Tank Breather
68 Hydraulic Oil Tank
74 High Flow Oil Check Valve
75 Hydraulic Control Valve
202 Return Oil from Hydraulic Oil Tank to High Flow Pump
203 Return Oil from High Flow Valve to Hydraulic Oil Tank
204 Supply Oil from High Flow Pump to High Flow Valve
205 Supply Oil from High Flow Pump to Hydraulic Control Valve
600 High Pressure Oil
604 Return Oil
The high flow pump (66) is for attachments that require a high hydraulic oil flow rate to operate. The high flow pump is located
on the side of the engine and driven by the engine auxiliary drive gear. See PowerTech™ E 2.4L and 3.0L Diesel Engines .
(CTM101019.) The high flow hydraulic pump draws oil from the hydraulic oil tank (68) and supplies a constant flow of oil to the
high flow valve (62). The high flow relief valve (64) is an adjustable relief valve. The high flow relief valve maintains a set
pressure in the high flow hydraulic circuit.
LEGEND:
1 Suction Port
2 Drive Gear
3 Driven Gear
4 Delivery Port
5 Housing
High Flow Pump
The high flow pump is a fixed displacement, external gear pump. An external gear pump has two gears in mesh, closely fitted
inside a housing (5). A drive shaft drives one gear (drive gear) (2), which in turn drives the other gear (driven gear) (3).
As the gears rotate and come out of mesh, oil enters the suction port (1) and fills the cavity between the gear teeth. Oil is
carried in the tooth cavity to the delivery port (4). As the gears come into mesh again oil is forced out of the delivery port and
sent through the system.
When the high flow switch is in the off position, the high flow pump sends supply oil (600) to the high flow valve. From the high
flow valve, return oil (604) flows back to the hydraulic oil tank. To enable high flow hydraulics, the high flow switch is
momentarily held in the on position. See High Flow Hydraulics—If Equipped . (Operator′s Manual.) When released, the high flow
switch returns to the run position. The high flow solenoid (Y7) is energized. The high flow spool (63) shifts and oil is blocked at
the high flow valve. High flow oil is sent to the hydraulic control valve (75), through the auxiliary valve spool, to the
attachment. With the high flow switch in the run position, high flow hydraulics are enabled until the high flow switch is turned
to the off position. The machine automatically returns to standard flow auxiliary hydraulics when the engine is shut off. For
more information, See Engagement and Monitor Unit (EMU) Circuit Theory of Operation . (Group 9015-15.)
Self Leveling Valve Operation—If Equipped
Self Leveling Valve

LEGEND:
99 Self Leveling Valve (if equipped)
100 Self Leveling Solenoid Spool (if equipped)
101 Orifice (if equipped)
102 Adjustable Orifice (if equipped)

103 Flow Divider Valve (if equipped)
104 Check Valve (if equipped)
105 Unloader Valve (if equipped)
106 Boom Cylinder (2 used)
110 Flow Rate Valve
113 Bucket Cylinder (2 used)
206 From Boom Cylinder (rod end) to Self Leveling Valve
207 From Hydraulic Control Valve (boom lower port) to Self Leveling Valve
208 From Bucket Cylinder (head end) to Self Leveling Valve
209 From Bucket Cylinder (rod end) to Self Leveling Valve
210 From Hydraulic Control Valve (bucket dump port) to Bucket Cylinder (head end)
211 From Hydraulic Control Valve (bucket curl port) to Bucket Cylinder (rod end)
606 Trapped Oil
The self leveling valve (99) automatically levels attachments as the boom is raised. Hydraulic oil from the rod end of the boom
cylinders (106) is routed to the head end of the bucket cylinders (113).
As the boom cylinders extend, oil from the boom cylinder (rod end) flows to the self leveling valve (206). When the self leveling
solenoid (Y38) is energized, the self leveling solenoid spool (100) shifts. See Engagement and Monitor Unit (EMU) Circuit Theory
of Operation . (Group 9015-15.) When the self leveling solenoid spool shifts, oil is blocked from exiting the self leveling valve.
Oil is directed to an adjustable orifice (102) and a fixed orifice (101) at the flow divider valve (103). The size difference between
the adjustable orifice and fixed orifice determines oil flow. Oil from the adjustable orifice flows to the head end of the bucket
cylinders (208). The adjustable orifice is screw adjustable. Deactivating the self leveling solenoid disables the self leveling
feature and allows boom float to function.
Resistance to movement of the bucket cylinders creates a pressure high enough to shift the unloader valve (105). As the
bucket cylinders extend, oil from the rod end flows past the unloader valve, through the hydraulic control valve (75), to the
hydraulic oil tank. The unloader valve prevents the bucket cylinders from dumping during the self leveling cycle. The self
leveling feature does not operate when the boom is lowered.
When the bucket cylinders are fully extended while the boom is being raised, the unloader valve shifts completely. Oil flow to
the head end of the bucket cylinders is changed. Oil is routed through the hydraulic control valve to the hydraulic oil tank to
allow the boom to continue to raise.
Hydraulic Pump Operation
Hydraulic Pump
LEGEND:
44 Hydraulic Pump
46 Charge Pump
139 Hydraulic Oil Tank-to-Hydraulic Pump Port
141 Hydraulic Pump Outlet Port
The hydraulic pump (44) is a fixed displacement, external gear pump. The hydraulic pump is mounted and driven off the end of
the hydrostatic pumps. The hydraulic pump draws hydraulic oil from the hydraulic oil tank port (139). The hydraulic pump
supplies a constant flow of supply oil to the hydraulic control valve through the hydraulic pump outlet port (141). For more
information, see Hydraulic Control Valve Operation . (Group 9025-05.)
LEGEND:
1 Suction Port
2 Drive Gear
3 Driven Gear
4 Delivery Port
5 Housing
Hydraulic Pump
An external gear pump has two gears in mesh, closely fitted inside a housing (5). A drive shaft drives one gear (drive gear) (2),
which in turn drives the other gear (driven gear) (3).

Hydraulic Fan Operation
Hydraulic Fan Component Location

LEGEND:
46 Charge Pump
51 Fan Bypass Valve 1 (if equipped)
53 Return Manifold
61 Hydraulic Fan Motor
161 Check Tee Fitting (if equipped)
212 Return Oil from Hydraulic Oil Cooler
Y33 Fan Bypass Solenoid 1 (if equipped)
Hydraulic Fan Schematic

LEGEND:
45 Charge Pump Housing
46 Charge Pump
52 Fan Bypass Spool 1 (if equipped)
53 Return Manifold
58 Fan Speed Solenoid Valve
60 Hydraulic Fan Manifold
124 Return Manifold Screen
162 Check Valve (830 kPa) (8.3 bar) (120 psi) (if equipped)
604 Return Oil

Standard Fan
A hydraulic fan is used to provide air flow for the cooling package. The fan drive system consists of:
Charge pump (46)

Fan speed solenoid valve (58)
Hydraulic fan speed solenoid (Y30)
Hydraulic fan motor (61)
The charge pump is connected to the output shaft of the hydraulic pump. Charge pressure oil (611) flows from the output port
of the charge pump to the hydraulic fan manifold (60). See Charge Pump Operation . (Group 9026-05.) The hydraulic fan speed
solenoid is a proportional relief solenoid used to control fan speed. The engine control unit (ECU) controls the hydraulic fan
speed solenoid. See Engine Control Unit (ECU) Circuit Theory of Operation . (Group 9015-15.) The hydraulic fan speed solenoid
moves the fan speed solenoid valve. The fan speed solenoid valve restricts oil flow to the opposite side of the hydraulic fan
motor. The flow restriction forces oil through the hydraulic fan motor. When oil flows through the hydraulic fan motor, the
hydraulic fan motor begins to rotate. When more oil is forced through the hydraulic fan motor due to increased restriction at
the fan speed solenoid valve, the hydraulic fan motor rotates faster. Charge oil leaves the hydraulic fan manifold, flows through
the hydraulic oil filter manifold (47), to the hydraulic and hydrostatic systems (201).
Hydraulic Reversing Fan Component Location

LEGEND:
46 Charge Pump
53 Return Manifold
55 Reversing Fan Valve (if equipped)

Hydraulic Reversing Fan Schematic

LEGEND:
46 Charge Pump
53 Return Manifold
56 Reversing Fan Solenoid Spool A (if equipped)
57 Reversing Fan Solenoid Spool B (if equipped)
59 Reversing Fan Direction Control Valve (if equipped)

604 Return Oil
Reversing Fan Valve (55)—If Equipped
→NOTE:
The hydraulic fan speed solenoid (Y30) and fan speed solenoid valve (58) move from the hydraulic fan
manifold (60) to the reversing fan valve when equipped with the reversing fan option.
The optional reversing fan valve is located between the charge pump (46) and hydraulic fan manifold (60). The reversing fan
valve reverses the fan to clean the machine cooling package of dirt and debris.
The reversing function is controlled manually with the reversing fan switch or automatically through the engine control unit
(ECU). Manual control is done using the reversing fan switch. See Control Panel Functions . (Operator′s Manual.) If set to
reverse automatically, the ECU reverses the fan at a preset interval. See Engine Control Unit (ECU) Circuit Theory of Operation .
(Group 9015-15.)
In forward operation, charge oil flows through reversing fan solenoid spool A (56) to the reversing fan direction control valve
(59) and hydraulic fan motor (61). Reversing fan solenoid spool B (57) blocks charge oil flow to the opposite side of the fan
circuit. The reversing fan direction control valve shifts due to the pressure difference at the ends of the spool. The opposite side
of the hydraulic fan motor is open to the output side of the fan speed solenoid valve (58). The hydraulic fan motor rotates in
the forward direction.
When the reversing fan function is engaged, hydraulic reversing fan solenoid A (Y31) and hydraulic reversing fan solenoid B
(Y32) act on reversing fan solenoid spool A and reversing fan solenoid spool B. Reversing fan solenoid spool A blocks charge oil
flow to the fan circuit. Reversing fan solenoid spool B allows oil flow to the reversing fan direction control valve and hydraulic
fan motor. The reversing fan direction control valve shifts due to the pressure difference at the ends of the spool. The opposite
side of the hydraulic fan motor is open to the output side of the fan speed solenoid valve. The hydraulic fan motor rotates in
the reverse direction.
Fan Bypass Valves (51 and 111)—If Equipped
Both fan bypass solenoid 1 (Y33) and fan bypass solenoid 2 (Y34) are wired in the same circuit from the engine control unit
(ECU) as the glow plug relay (K2). When the ECU energizes the glow plug relay during engine preheat and after engine startup,
both fan bypass solenoids are also energized.
When fan bypass solenoid 1(Y33) is energized, the fan bypass spool 1 (52) shifts. This directs charge oil to the check tee fitting
(161).
The check tee fitting has two internal check valves. One check valve (163) is set to open at 35 kPa (0.35 bar) (5 psi) and the
other check valve (162) is set to open at 830 kPa (8.3 bar) (120 psi).
Charge oil through the 35 kPa (0.35 bar) (5 psi) check valve directs flow to the hydrostatic pumps, hydraulic fan system, and
hydraulic oil filter manifold.
Charge oil through the 830 kPa (8.3 bar) (120 psi) check valve directs flow to fan bypass valve 2 (111). With fan bypass
solenoid 2 (Y34) energized and fan bypass valve spool 2 (112) shifted, a direct path for charge oil to flow to the hydraulic oil
tank (68) is opened.
This direct route to return reduces charge pressure in the system and effectively bypasses the hydraulic fan system and filter.
Charge oil flow through the 35 kPa (0.35 bar) (5 psi) check valve provides the necessary minimal flow to the hydrostatic pumps
at engine startup. This action puts less load on the charge pump and reduces engine load for cold weather starting.
When the bypass solenoids are de-energized, both valve spools shift back to their normally closed positions, but at varying
rates of speed.
Fan bypass valve spool 2 (112) shifts immediately, blocking the flow of charge oil to the hydraulic oil tank. Charge oil flow now
goes completely to the hydrostatic pumps and hydraulic system, still bypassing the hydraulic fan system and filter.
Fan bypass valve spool 1 (52) shifts at a slower rate to prevent pressure spikes in the system. Once the valve has closed,
charge oil is routed first through the hydraulic fan system and hydraulic oil filter (52) before going on to the hydrostatic pumps
and hydraulic system.
Hydraulic Control Valve Operation
Hydraulic Control Valve Component Location

LEGEND:
76 Hydraulic System Relief Valve
78 Boom Check Valve
79 Boom Spool
81 Boom Up Circuit Relief and Anticavitation Valve

84 Bucket Check Valve
85 Bucket Spool
87 Bucket Dump Circuit Relief and Anticavitation Valve
89 Bucket Curl Circuit Relief and Anticavitation Valve
92 Auxiliary Check Valve
93 Auxiliary Spool
95 Plug
96 Plug
98 Port Lock Spool
205 Supply Oil from High Flow Pump to Hydraulic Control Valve
213 Charge Oil Port from Pilot Control Accumulator Manifold
214 Supply Oil Port from Hydraulic Pump
215 Boom Up Work Port
216 Boom Down Work Port
217 Bucket Curl Work Port
218 Bucket Dump Work Port
219 Female Auxiliary Work Port
220 Male Auxiliary Work Port
221 Return Oil Work Port
222 Charge Oil Pilot Control Port
223 Return Oil Port to Hydraulic Oil Cooler
Hydraulic Control Valve Schematic

LEGEND:
78 Boom Check Valve
79 Boom Spool
85 Bucket Spool
91 Auxiliary Solenoid Spool
93 Auxiliary Spool
95 Plug
96 Plug
97 Port Lock Solenoid Spool
98 Port Lock Spool

110 Flow Rate Valve
205 High Flow Supply Oil Port
213 Charge Oil Port from Pilot Control Accumulator Manifold
214 Supply Oil Port from Hydraulic Pump
215 Boom Up Work Port
216 Boom Down Work Port
217 Bucket Curl Work Port
218 Bucket Dump Work Port
219 Female Auxiliary Work Port
220 Male Auxiliary Work Port
221 Return Oil Work Port
222 Charge Oil Pilot Control Port
223 Return Oil Port to Hydraulic Oil Cooler
604 Return Oil
606 Trapped Oil
The hydraulic control valve (75) is located in the front center of the machine. See Hydraulic System Component Location .
(Group 9025-15.) The hydraulic control valve includes three valve spools and pressure relief valves for each individual circuit.
The hydraulic control valve also includes a port lock spool (98) and a hydraulic system relief valve (76) for entire hydraulic
system.
The hydraulic control valve is an open-center control valve. In an open-center control valve, the first valve spool takes priority
over the next valve spool downstream in the circuit. The hydraulic pump provides a continuous flow of hydraulic oil through the
supply oil port from hydraulic pump (214). If the valve spools are not operated, hydraulic oil flow passes through the open
center passage of each valve spool. Hydraulic oil then flows out the return oil port to hydraulic oil cooler (223).
Hydraulic System Relief Valve
The hydraulic system relief valve (76) protects the hydraulic system and hydraulic pump from excessive pressure. If needed,
the hydraulic system relief valve can be adjusted to hydraulic system relief specifications. See Hydraulic System Relief Valve
Test . (Group 9025-25.)
Port Lock Solenoid and Port Lock Spool
A port lock solenoid (Y4) and port lock spool (98) are incorporated into the control valve. The port lock solenoid and port lock
spool are a safety device and are part of the interlock logic. When the port lock solenoid is de-energized, spring pressure shifts
the port lock spool and prevents oil flow to the boom and bucket cylinders. When the port lock solenoid is energized, oil
pressure overcomes spring pressure at the port lock spool. The port lock spool shifts to allow oil flow to the boom and bucket
cylinders. For interlock logic, see Engagement and Monitor Unit (EMU) Circuit Theory of Operation . (Group 9015-15.)
Boom Cylinder Circuit
The first spool in the series, and therefore first priority, controls the boom cylinder circuit. When the boom spool (79) is
actuated, the open-center port is blocked. Oil is directed to the appropriate side of the boom cylinder out boom work port (215
or 216). Return oil from the boom cylinders flows into the control valve through the opposite boom work port. Return oil flows
through the boom spool and is available as supply oil to the bucket and auxiliary spools.
A flow rate valve (110) is in the boom lower circuit. The flow rate valve restricts return oil flow during a boom down function.
The restriction of the return oil flow allows for greater control of the boom during a boom down function.
The boom up circuit relief and anticavitation valve (81) protects the boom circuit from excessive pressure in the boom up
circuit. The boom up circuit relief and anticavitation valve also prevents cavitation in the boom cylinders. The boom check
valve (78) prevents unwanted movement in the boom circuit during initial movement of the boom spool.
A boom spool lock solenoid (Y2) is mounted to the boom spool as a safety device and is part of the interlock logic. The boom
spool lock solenoid controls a mechanical lockout pin on the boom spool. When the lockout pin is engaged, the boom spool is
locked. Hydraulic oil flow to the boom circuit is blocked. When the boom spool lock solenoid is energized, the lockout pin is
disengaged. The boom spool is unlocked and hydraulic oil flow is available in the boom circuit. For interlock logic, see
Engagement and Monitor Unit (EMU) Circuit Theory of Operation . (Group 9015-15.)
Bucket Cylinder Circuit
The second spool in the series controls the bucket cylinder circuit. When the bucket spool (85) is actuated, the open-center
Section 9025 - HYDRAULIC SYSTEM Group 15: Diagnostic Information
port is blocked. Oil is directed to the appropriate side of the bucket cylinders out bucket work port (217 or 218). Return oil from
the bucket cylinders flows into the control valve through the opposite bucket work port. Return oil flows through the bucket
spool and is available as supply oil to the auxiliary spool.
The bucket dump circuit relief and anticavitation valve (87) and bucket curl circuit relief and anticavitation valve (89) protect
the bucket circuit from excessive pressure. The bucket dump circuit relief and anticavitation valve and bucket curl circuit relief
and anticavitation valve also prevent cavitation in the bucket cylinders. The bucket check valve (84) prevents unwanted
movement in the bucket circuit during initial movement of the bucket spool.
A bucket spool lock solenoid (Y3) is mounted to the bucket spool as a safety device and is part of the interlock logic. The
bucket spool lock solenoid controls a mechanical lockout pin on the bucket spool. When the lockout pin is engaged, the bucket
spool is locked. Hydraulic oil flow to the bucket circuit is blocked. When the bucket spool lock solenoid is energized, the lockout
pin is disengaged. The bucket spool is unlocked and hydraulic oil flow is available in the bucket circuit. For interlock logic, see
Engagement and Monitor Unit (EMU) Circuit Theory of Operation . (Group 9015-15.)
Auxiliary Hydraulic Circuit
→NOTE:
Auxiliary port (male) solenoid (Y23) is left auxiliary solenoid. Solenoid (Y23) controls flow of pressure oil
from male auxiliary work port (220) to male auxiliary connector(s).
Auxiliary port (female) solenoid (Y24) is right auxiliary solenoid. Solenoid (Y24) controls flow of pressure
oil from female auxiliary work port (219) to female auxiliary connector(s).
The third spool in the series provides hydraulic oil to operate auxiliary hydraulic attachments. When auxiliary port (male)
solenoid (Y23) or auxiliary port (female) solenoid (Y24) is energized, the corresponding auxiliary solenoid spool (91 or 94)
shifts. When the auxiliary solenoid spool shifts, charge oil from the pilot control port (222) flows to the selected end of the
auxiliary spool (93). When the auxiliary spool is actuated, the open-center port is blocked. Oil is directed to the appropriate side
of the auxiliary attachment circuit through auxiliary work ports (219 and 220). Return oil from the auxiliary attachment flows
into the control valve through the opposite auxiliary work port. Return oil flows through the auxiliary spool out the return oil
port to hydraulic oil cooler (223).
If equipped, high flow oil flows in the high flow supply oil port (205) to the auxiliary spool to supply high flow oil to auxiliary
attachments. See High Flow Pump Operation—If Equipped . (Group 9025-05.)
The auxiliary check valve (92) prevents unwanted movement in the circuit during initial movement of the auxiliary spool. The
auxiliary check valve also blocks the flow of high flow oil to the boom and bucket circuits.

Hydraulic System Schematic
Hydraulic System Schematic (page 1 of 2)
LEGEND:
43 Hydraulic Pump Housing
44 Hydraulic Pump
46 Charge Pump
53 Return Manifold
56 Reversing Fan Solenoid Spool A (if equipped)
57 Reversing Fan Solenoid Spool B (if equipped)
59 Reversing Fan Direction Control Valve (if equipped)
69 Hydraulic Oil Cooler
70 Hydraulic Oil Cooler Bypass Valve (if equipped)
604 Return Oil
700 Supply Oil from Hydraulic Pump to Hydraulic Control Valve
701 Charge Oil from Charge Pump to Pilot Control Accumulator Manifold
703 Return Oil from High Flow Valve to Return Manifold
704 Return Oil from Hydraulic Control Valve to Hydraulic Oil Cooler
705 Return Oil from Auxiliary Case Drain to Return Manifold
706 Return Oil from Hydraulic Control Valve to Return Manifold
707 Charge Oil to Hydrostatic Pumps (see Hydrostatic System Schematic)
Hydraulic System Schematic (page 2 of 2)
LEGEND:
54 Attenuator (if equipped)
63 High Flow Spool (if equipped)
64 High Flow Relief Valve (if equipped)
65 High Flow Pump Housing (if equipped)
71 Pilot Control Accumulator Manifold
72 Pilot Control Accumulator
73 Pilot Control Check Valve
74 High Flow Oil Check Valve
78 Boom Check Valve
79 Boom Spool
85 Bucket Spool
93 Auxiliary Spool
95 Plug
96 Plug
97 Port Lock Solenoid Spool
98 Port Lock Spool
100 Self Leveling Solenoid Spool (if equipped)
101 Orifice (if equipped)
102 Adjustable Orifice (if equipped)
103 Flow Divider Valve (if equipped)
104 Check Valve (if equipped)
105 Unloader Valve (if equipped)
110 Flow Rate Orifice and Check Valve
114 Auxiliary Coupler Manifold
115 Female Auxiliary Port
116 Female High Flow Auxiliary Port (if equipped)
117 Male High Flow Auxiliary Port (if equipped)
118 Male Auxiliary Port
119 Auxiliary Case Drain Port (if equipped)
604 Return Oil
606 Trapped Oil
609 Pilot Oil
700 Supply Oil from Hydraulic Pump to Hydraulic Control Valve
703 Return Oil from High Flow Valve to Return Manifold
704 Return Oil from Hydraulic Control Valve to Hydraulic Oil Cooler
705 Return Oil from Auxiliary Case Drain to Return Manifold
706 Return Oil from Hydraulic Control Valve to Return Manifold
Hydraulic System Component Location

→NOTE:
333D is shown, component location for 329D is similar.
Hydraulic System Component Location—333D Shown (329D is similar)
LEGEND:
44 Hydraulic Pump
46 Charge Pump
51 Fan Bypass Valve (if equipped)
53 Return Manifold
54 Attenuator (if equipped)
70 Hydraulic Oil Cooler Bypass Valve (if equipped)
114 Auxiliary Coupler Manifold
Diagnose Hydraulic System Malfunctions
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely and most difficult to verify.
See No Hydraulic Functions . (Group 9025-15.)

See Boom Will Not Raise . (Group 9025-15.)
See Boom Will Not Lower . (Group 9025-15.)
See Bucket Will Not Dump . (Group 9025-15.)
See Bucket Will Not Curl . (Group 9025-15.)
See Bucket Will Not Self Level When Boom is Raised . (Group 9025-15.)
See Bucket Dumps During Self Leveling Cycle . (Group 9025-15.)
See Boom Drifts Down . (Group 9025-15.)
See Boom Drifts Up . (Group 9025-15.)
See Bucket Drifts Down . (Group 9025-15.)
See Bucket Drifts Up . (Group 9025-15.)
See Hydraulic Functions Slow or No Power . (Group 9025-15.)
See Hydraulic Functions “Jerky” or “Spongy” . (Group 9025-15.)
See Hydraulic System Noise . (Group 9025-15.)
See Pedals Will Not Move . (Group 9025-15.)
See Hydraulic Oil Overheats . (Group 9025-15.)
See Hydraulic Fan System Malfunctions . (Group 9025-15.)
See Hydraulic Fan Will Not Reverse Direction . (Group 9025-15.)
No Hydraulic Functions
73
No Hydraulic Functions Diagnostic Procedure

( 1 ) Diagnostic Trouble Codes (DTCs) Check
Action:
Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes (DTCs) . (Group 9015-20.)
Result:
YES:Resolve diagnostic trouble codes.

NO:Go to Low Hydraulic Oil Level.
( 2 ) Low Hydraulic Oil Level
Action:
Check hydraulic oil reservoir level. See Check Hydraulic Reservoir Oil Level . (Operator′s Manual.)
Is oil level correct?
Result:
YES:Go to Interlock Logic Sequence Not Performed Correctly.

NO:Fill reservoir to correct level with appropriate hydraulic oil. For recommended oil, see Hydraulic and Hydrostatic Oil .
( 3 ) Interlock Logic Sequence Not Performed Correctly
Action:
Check that hydraulic functions are enabled. For Interlock Logic, see Engagement and Monitor Unit (EMU) Circuit Theory of
Are hydraulic functions enabled?
Result:
YES:Go to Port Lock Solenoid Valve and Port Lock Spool.

NO:Perform correct Interlock Logic sequence to enable hydraulics.
( 4 ) Port Lock Solenoid Valve and Port Lock Spool
Action:
Do auxiliary hydraulic functions operate, but boom and bucket functions do not?
Result:
YES:Check port lock solenoid valve and port lock spool. See Port Lock Solenoid Valve and Port Lock Spool Test . (Group
9025-25.)
NO: Go to Boom and Bucket Spool Lock Solenoid .
( 5 ) Boom and Bucket Spool Lock Solenoid
Action:
Do boom and bucket controls move freely?
Result:
YES:Go to Hydraulic System Relief Valve.
NO:Check boom and bucket spool lock. See Boom and Bucket Spool Lock Solenoid Test . (Group 9025-25.)
( 6 ) Hydraulic System Relief Valve
Action:
Check hydraulic system relief valve pressure.

See Hydraulic System Relief Valve Test . (Group 9025-25.)
Is hydraulic system relief valve pressure within specification?
Result:
YES:Go to Hydraulic Pump.

NO:If below specification, but not zero, replace system relief valve. If relief pressure is at or near zero, go to Hydraulic Pump.
( 7 ) Hydraulic Pump
Action:
Check hydraulic pump flow. See Hydraulic Pump Flow Test . (Group 9025-25.)
Is hydraulic pump flow within specification?
Result:
YES:Go to Control Valve Not Functioning Properly.

NO:Replace hydraulic pump. See Hydraulic Pump Remove and Install and see Hydraulic Pump Disassemble and Assemble .
(Group 3160.)
( 8 ) Control Valve Not Functioning Properly
Action:
Inspect control valve. Ensure that auxiliary plug is installed and free of leaks.
See Control Valve Disassemble and Assemble . (Group 3160.)
Is control valve worn or spools bent or binding in bores?
Result:
YES:Repair or replace control valve.

NO:Checks complete.
Boom Will Not Raise

73
Boom Will Not Raise Diagnostic Procedure

Action:
Result:

Action:
Result:
YES:Go to Bucket Overloaded.

( 3 ) Bucket Overloaded
Action:
Check operating capacities. See Rated Operating Capacity or see Pallet Fork Lift Chart . (Operator′s Manual.)
Is bucket overloaded?
Result:
YES:Reduce bucket load.

NO:Go to Port Lock Solenoid Valve and Port Lock Spool.
Action:
Result:
9025-25.)
NO:Go to Boom and Bucket Spool Lock Solenoid.
Action:
Result:
YES:Go to Circuit Relief Valve Malfunction.

( 6 ) Circuit Relief Valve Malfunction
Action:
Check boom up circuit relief valve pressure. See Circuit Relief Valve Test . (Group 9025-25.)
Is boom up circuit relief valve pressure correct?
Result:
YES:Go to Control Valve Linkage or Spool Binding.

NO:Replace boom up circuit relief valve. See Control Valve Disassemble and Assemble . (Group 3160.)
( 7 ) Control Valve Linkage or Spool Binding
Action:
Inspect control valve and linkage.

Is linkage in good condition and control valve spool not binding or damaged?
Result:
YES:Go to Stuck Pivot Pins.

NO:Repair or replace control valve linkage. Repair or replace control valve spool. See Control Valve Remove and Install .
(Group 3160.) See Control Valve Disassemble and Assemble . (Group 3160.)
( 8 ) Stuck Pivot Pins
Action:
Check pivot pins for proper operation.

Are pivot pins stuck or binding?
Result:
YES:Repair or replace pivot pins.

NO:Go to Hydraulic Cylinder Leakage.
( 9 ) Hydraulic Cylinder Leakage
Action:
Check hydraulic cylinders for leakage. See Cylinder Identification . (CTM120519.)

Are hydraulic cylinders leaking?
Result:
YES:Repair or replace hydraulic cylinders.

NO:Go to Bent or Damaged Cylinder Rods.
( 10 ) Bent or Damaged Cylinder Rods
Action:
Check hydraulic cylinders for bent or damaged rods. See Cylinder Identification . (CTM120519.)
Are hydraulic cylinder rods bent or damaged?
Result:
YES:Repair or replace cylinder rods. See Cylinder Identification . (CTM120519.)

NO:Go to Hydraulic System Relief Valve.
Action:

Result:

NO:If below specification, but not zero, replace hydraulic system relief valve. If relief pressure is at or near zero, go to
Hydraulic Pump.
Action:
Result:
NO:Repair or replace hydraulic pump. See Hydraulic Pump Remove and Install and see Hydraulic Pump Disassemble and
Assemble . (Group 3160.)
Boom Will Not Lower

73
Boom Will Not Lower Diagnostic Procedure

Action:
Result:

NO:Go to Boom Lock Engaged.
( 2 ) Boom Lock Engaged
Action:
Check to see if boom lock is engaged. See Boom Lock . (Operator′s Manual.)
Is boom lock engaged?
Result:
YES:Release boom lock.

Action:
Result:

Action:
Result:
9025-25.)
Action:
Result:

Action:

Result:

Action:

Result:

Action:
Result:

NO:Go to Plugged Flow Rate Orifice and Check Valve.
( 9 ) Plugged Flow Rate Orifice and Check Valve
Action:
Inspect flow rate orifice and check valve located in boom up work port. See Hydraulic Control Valve Operation . (Group
9025-05.)
Is flow rate orifice and check valve dirty?
Result:
YES:Clean flow rate orifice and check valve.

Action:

Result:
Hydraulic Pump.
Action:
Result:
Bucket Will Not Dump

73
Bucket Will Not Dump Diagnostic Procedure

Action:
Result:

Action:
Result:

Action:
Result:
9025-25.)
Action:
Result:

Action:
Check bucket dump circuit relief valve pressure. See Circuit Relief Valve Test . (Group 9025-25.)
Is bucket dump circuit relief valve pressure correct?
Result:

NO:Replace bucket dump circuit relief valve. See Control Valve Disassemble and Assemble . (Group 3160.)
Action:

Result:

Action:

Result:

Action:

Result:

Action:
Result:

NO:Checks complete.
Bucket Will Not Curl

73
Bucket Will Not Curl Diagnostic Procedure

Action:
Result:

Action:
Result:

Action:
Result:

NO:Go to Port Lock Solenoid Valve and Port Lock Spool.
Action:
Result:
9025-25.)
Action:
Result:

Action:
Check bucket curl circuit relief valve pressure. See Circuit Relief Valve Test . (Group 9025-25.)
Is bucket curl circuit relief valve pressure correct?
Result:

NO:Replace bucket curl circuit relief valve. See Control Valve Disassemble and Assemble . (Group 3160.)
Action:

Result:

Action:

Result:

Action:

Result:

Action:
Result:

Action:

Result:

Hydraulic Pump.
Action:
Result:
Bucket Will Not Self Level When Boom is Raised
73
Bucket Will Not Self Level When Boom is Raised Diagnostic Procedure
Action:
Result:

NO:Go to Self Leveling Function Disabled.
( 2 ) Self Leveling Function Disabled
Action:
Ensure that self leveling function is enabled. See Self Leveling Valve Operation—If Equipped . (Operator′s Manual.)
Is self leveling function enabled?
Result:
YES:Go to Adjustable Orifice Screw Turned in Completely.

NO:Enable self leveling function.
( 3 ) Adjustable Orifice Screw Turned in Completely
Action:
Turn self leveling screw out to set desired self level rate. See Self Leveling Valve Operation—If Equipped . (Group 9025-05.)
Does self leveling screw adjustment correct problem?
Result:
NO:Go to Check Valve Removed from Self Leveling Valve.
( 4 ) Check Valve Removed from Self Leveling Valve
Action:
Verify that check valve is installed in self leveling valve. See Self Leveling Valve Operation—If Equipped . (Group 9025-05.)
Is check valve installed correctly?
Result:
NO:Install check valve in self leveling valve. See Self Leveling Valve Remove and Install . (Group 3160.)
Bucket Dumps During Self Leveling Cycle
73
Bucket Dumps During Self Leveling Cycle Diagnostic Procedure

Action:
Result:

NO:Go to Adjustable Orifice Screw Out of Adjustment.
( 2 ) Adjustable Orifice Screw Out of Adjustment
Action:
Turn self leveling orifice screw to set desired self level rate. See Self Leveling Valve Operation—If Equipped . (Group 9025-05.)
Does self leveling orifice adjustment correct problem?
Result:
NO:Self leveling valve malfunction. Repair or replace self leveling valve. See Self Leveling Valve Remove and Install . (Group
3160.)
Boom Drifts Down

73
Boom Drifts Down Diagnostic Procedure

Action:
Result:

NO:Go to Drift Check.
( 2 ) Drift Check
Action:
Check boom down drift. See Boom Down Drift Check . (9005-10.)
Is boom down drift within specification?
Result:
YES:Done; normal machine operation.

NO:Go to Circuit Relief Valve Malfunction.
Action:
Check boom up circuit relief valve pressure. See Circuit Relief Valve Test . (Group 9025-25.)
Is boom up circuit relief valve pressure correct?
Result:
YES:Go to Boom Check Valve.

NO:Replace boom up circuit relief valve. See Control Valve Disassemble and Assemble . (Group 3160.)
( 4 ) Boom Check Valve
Action:
Check boom check valve.

Is boom check valve functioning correctly?
Result:

NO:Replace boom check valve.
Action:

Result:
YES:Go to Hydraulic Cylinder Leakage.

Action:

Result:

Action:
Result:

NO:Check complete.
Boom Drifts Up
73
Boom Drifts Up Diagnostic Procedure

Action:
Result:

( 2 ) Drift Check
Action:
Check boom up drift. See Boom Up Drift Check . (9005-10.)

Is boom up drift within specification?
Result:

NO:Go to Self Leveling Valve Malfunction.
( 3 ) Self Leveling Valve Malfunction
Action:
Check self leveling valve adjustment. See Self Leveling Valve Operation—If Equipped . (Group 9025-05.)
Is self leveling valve operating correctly?
Result:
YES:Go to Boom Check Valve.

NO:Adjust self leveling valve.
( 4 ) Boom Check Valve
Action:
Check boom check valve.

Is boom check valve functioning correctly?
Result:

NO:Replace boom check valve.
Action:

Result:

Action:

Result:

Action:
Result:

NO:Check complete.
Bucket Drifts Down

73
Bucket Drifts Down Diagnostic Procedure

Action:
Result:

( 2 ) Drift Check
Action:
Check bucket dump drift. See Bucket Dump Drift Check . (9005-10.)
Is bucket dump drift within specification?
Result:

Action:
Result:

Action:
Check bucket curl circuit relief valve pressure. See Circuit Relief Valve Test . (Group 9025-25.)
Is bucket curl circuit relief valve pressure correct?
Result:
YES:Go to Bucket Check Valve.

NO:Replace bucket curl circuit relief valve. See Control Valve Disassemble and Assemble . (Group 3160.)
( 5 ) Bucket Check Valve
Action:
Check bucket check valve.

Is bucket check valve functioning correctly?
Result:

NO:Replace bucket check valve.
Action:

Result:

Action:

Result:

Action:
Result:

NO:Check complete.
Bucket Drifts Up
73
Bucket Drifts Up Diagnostic Procedure

Action:
Result:

( 2 ) Drift Check
Action:
Check bucket curl drift. See Bucket Curl Drift Check . (9005-10.)
Is bucket curl drift within specification?
Result:

Action:
Result:

Action:
Check bucket dump circuit relief valve pressure. See Circuit Relief Valve Test . (Group 9025-25.)
Is bucket dump circuit relief valve pressure correct?
Result:
YES:Go to Bucket Check Valve.

NO:Replace bucket dump circuit relief valve. See Control Valve Disassemble and Assemble . (Group 3160.)
( 5 ) Bucket Check Valve
Action:
Check bucket check valve.

Is bucket check valve functioning correctly?
Result:

NO:Replace bucket check valve.
Action:

Result:

Action:

Result:

Action:
Result:

NO:Check complete.
Hydraulic Functions Slow or No Power

73
Hydraulic Functions Slow or No Power Diagnostic Procedure

Action:
Result:

Action:
Result:

Action:
Result:

Action:

Result:
YES:Go to Air in Hydraulic Cylinders.

NO:Replace hydraulic system relief valve. See Control Valve Remove and Install . (Group 3160.) See Control Valve Disassemble
and Assemble . (Group 3160.)
( 5 ) Air in Hydraulic Cylinders
Action:
Operate hydraulic functions to bleed hydraulic system. See Hydraulic Cylinder Bleed Procedure . (Group 3160.)
Does bleeding hydraulic cylinders correct slow or no power condition?
Result:
NO:Go to Boom or Bucket Spool Lock Solenoid Malfunction.
( 6 ) Boom or Bucket Spool Lock Solenoid Malfunction
Action:
→NOTE:
Auxiliary spool does not use a spool lock solenoid.
Check function of boom and bucket spool lock solenoids. See Solenoid Test . (Group 9015-20.)
Are spool lock solenoids functioning correctly?
Result:

NO:Replace spool lock solenoid.
Action:

Result:

Action:

Result:

Action:

Result:

Action:
Result:

NO:Go to Hydraulic Pump.
Action:
Result:
YES:Go to High Flow Hydraulic Pump Worn or Damaged.

( 12 ) High Flow Hydraulic Pump Worn or Damaged
Action:
Check high flow hydraulic pump flow. See Hydraulic Pump Flow Test . (Group 9025-25.)
Is high flow hydraulic pump flow within specification?
Result:
YES:Go to Control Valve Not Functioning Properly.

NO:Repair or replace high flow hydraulic pump. See High Flow Hydraulic Pump Remove and Install . (Group 3160.)
( 13 ) Control Valve Not Functioning Properly
Action:
Inspect control valve. Ensure that auxiliary plug is installed and free of leaks.
Is control valve worn or spools bent or binding in bores?
Result:
YES:Repair or replace control valve.

NO:Checks complete.
Hydraulic Functions “Jerky” or “Spongy”

73
Hydraulic Functions “Jerky” or “Spongy” Diagnostic Procedure

Action:
Result:

Action:
Result:
YES:Go to Air in Hydraulic System.

( 3 ) Air in Hydraulic System
Action:
Check for air leak into hydraulic system on suction side of hydraulic pump.
Are suction lines or hoses loose or leaking, allowing air into hydraulic system?
Result:
YES:Repair or replace hydraulic lines or hoses.

NO:Go to Control Valve Linkage or Spool Binding.
Action:

Result:

Action:

Result:

Action:

Result:

Action:
Result:

Action:

Result:

NO:Replace hydraulic system relief valve. See Control Valve Remove and Install . (Group 3160.) See Control Valve Disassemble
and Assemble . (Group 3160.)
Action:
Result:

Action:
Result:
Hydraulic System Noise

73
Hydraulic System Noise Diagnostic Procedure

Action:
Result:

Action:
Result:

Action:
Check for air leak into hydraulic system on suction side of hydraulic pump.
Are suction lines or hoses loose or leaking, allowing air into hydraulic system?
Result:

NO:Go to Bucket Overloaded.
Action:
Result:

NO:Go to Control Valve Linkage or Spool Binding.
Action:

Result:

Action:

Result:

Hydraulic Pump .
Action:
Result:
YES:Go to Charge Pump Worn or Damaged.

( 8 ) Charge Pump Worn or Damaged
Action:
Check charge pump flow. See Charge Pump Flow Test . (Group 9025-25.)
Is charge pump flow within specification?
Result:

NO:Repair or replace charge pump. See Charge Pump Remove and Install . (Group 3160.)
Action:
Result:
YES:Go to Hydrostatic Pump Worn or Damaged.

( 10 ) Hydrostatic Pump Worn or Damaged
Action:
Check hydrostatic pump flow. See Hydrostatic Pump Flow Test . (Group 9026-25.)
Is hydrostatic pump flows within specification?
Result:
NO:Repair or replace hydrostatic pump. See Hydrostatic Pump Remove and Install or see Hydrostatic Pump
Disassemble—329D, 332D, 333D . (Group 0360.)
Pedals Will Not Move
73
Pedals Will Not Move Diagnostic Procedure

Action:
Result:

NO:Go to Boom or Bucket Spool Lock Solenoid Malfunction.
( 2 ) Boom or Bucket Spool Lock Solenoid Malfunction
Action:
→NOTE:
Auxiliary spool does not use a spool lock solenoid.
Check function of boom and bucket spool lock solenoids. See Solenoid Test . (Group 9015-20.)
Are spool lock solenoids functioning correctly?
Result:

NO:Replace spool lock solenoid.
Action:

Result:
Hydraulic Oil Overheats

73
Hydraulic Oil Overheats Diagnostic Procedure

Action:
Result:

Action:
Result:
YES:Go to Hydraulic System Overloaded.

( 3 ) Hydraulic System Overloaded
Action:
Check for hydraulic system overload: bucket overloaded, improperly matched attachment, or attachment pushed beyond
machine limits. See Rated Operating Capacity or see Pallet Fork Lift Chart . (Operator′s Manual.)
Is hydraulic system overloaded?
Result:
YES:Reduce load on machine hydraulic system.

NO:Go to Air Flow Restricted Through Hydraulic Oil Cooler.
( 4 ) Air Flow Restricted Through Hydraulic Oil Cooler
Action:
Check hydraulic oil cooler for air flow restriction through cooler. Check radiator for damage or air restriction.
Is air flow restricted through oil cooler or radiator?
Result:
YES:Clean hydraulic oil cooler and radiator. See Inspect and Clean Cooling Package . (Operator′s Manual.)
NO:Go to Slow Hydraulic Fan Motor Speed.
( 5 ) Slow Hydraulic Fan Motor Speed
Action:
Check hydraulic fan speed. See Hydraulic Fan Motor Speed Test . (Group 9025-25.)
Is hydraulic fan motor speed within specification?
Result:

NO:Diagnose fan system malfunction. See Hydraulic Fan System Malfunctions . (Group 9025-15.)
Action:

Result:

NO:If below specification, but not zero, replace hydraulic system relief valve. If relief pressure is at or near zero, go to Stuck
Pivot Pins .
Action:

Result:

Action:

Result:

Action:
Result:

NO:Go to Hydraulic Pump.
Action:
Result:
YES:Go to Charge Pump Worn or Damaged.

( 11 ) Charge Pump Worn or Damaged
Action:
Result:

Action:
Result:

Action:
Is hydrostatic pump flows within specification?
Result:
YES:Go to Hydrostatic Motors Worn or Damaged.

NO:Repair or replace hydrostatic pump. See Hydrostatic Pump Remove and Install or see Hydrostatic Pump
( 14 ) Hydrostatic Motors Worn or Damaged
Action:
Remove hydrostatic motors and inspect for wear.

See Hydrostatic Pump Remove and Install . (Group 0360.)
Are hydrostatic motors damaged or worn excessively?
Result:
YES:Repair or replace hydrostatic motor.

NO:Checks complete.
Hydraulic Fan System Malfunctions

73
Hydraulic Fan System Malfunctions Diagnostic Procedure

Action:
Result:

Action:
Result:
YES:Go to Hydraulic Fan Speed Check (System Cold).

( 3 ) Hydraulic Fan Speed Check (System Cold)
Action:
→NOTE:
Machines equipped with the the optional cold start package are equipped with two fan bypass valves.
The fan bypass valves are used during engine startup to bypass the hydraulic fan system and filter,
which reduces both charge pressure in the system and engine load for cold weather starting.
Verify fan bypass valve function if fan is not spinning or fan speed is significantly below normal fan speed
specification after engine has been running for several minutes. See Fan Bypass Valve Test . (Group
9025-25.)
Check fan speed at fast idle with machine cool (hydraulic oil, engine coolant, and manifold air temperatures less than 38°C
[100°F]). See Hydraulic Fan Motor Speed Test . (Group 9025-25.)
Is fan speed below 1500 rpm at fast idle?
Result:
YES:Go to Charge Oil Pressure Check (System Cold).

NO:Check electrical connections to hydraulic fan speed solenoid (Y30). See Main Harness (W3) Component Location or see Fan
Speed Solenoid Harness (W9) Component Location . (Group 9015-10.) Check resistance of hydraulic fan speed solenoid (Y30).
See Electrical Component Checks . (Group 9015-20.) Remove hydraulic fan speed solenoid. Inspect for any debris that would
prevent normal solenoid operation.
( 4 ) Charge Oil Pressure Check (System Cold)
Action:
Check charge oil pressure at hydraulic oil filter manifold with machine cool (hydraulic oil, engine coolant, and manifold air
temperatures less than 38°C [100°F]). See Charge Pressure Relief Valve Test . (Group 9025-25.)
Is charge oil pressure at hydraulic oil filter manifold above minimum specification?
Result:

NO:Check charge pump flow. See Charge Pump Flow Test . (Group 902525.) If charge pump flow meets specification, replace
charge pressure relief valve.
Action:
Check charge oil pressure at pump outlet at fast idle with machine cool (systems less than 38°C [100°F]).
Compare charge oil pressure at pump outlet to pressure at hydraulic oil filter manifold.
→NOTE:
Pressure difference should be approximately 1380—2070 kPa (14—21 bar) (200—300 psi).
Is pressure difference greater than 6900 kPa (69 bar) (1000 psi) with machine cool (less than 38°C [100°F])?
Result:
YES:Remove hydraulic fan speed solenoid. Inspect for any debris or other malfunction that would prevent normal solenoid
operation.
NO:Go to Charge Oil Pressure Check (Operating Temperature).
( 5 ) Charge Oil Pressure Check (Operating Temperature)
Action:
→NOTE:
Disconnecting connector to hydraulic fan speed solenoid (Y30) will cause fan to operate at maximum
speed.
Disconnect connector from hydraulic fan speed solenoid (Y30). See Main Harness (W3) Component Location or see Fan Speed
Solenoid Harness (W9) Component Location . (Group 9015-10.)
Check charge oil pressure at hydraulic oil filter manifold with machine at operating temperature. See Charge Pressure Relief
Valve Test . (Group 9025-25.)
Is charge oil pressure at hydraulic oil filter manifold above minimum specification?
Result:

NO:Check charge pump flow. See Charge Pump Flow Test . (Group 9025-25.) If charge pump flow meets specification, replace
Action:
Check charge oil pressure at pump outlet at fast idle.

Compare charge oil pressure at pump outlet to pressure at hydraulic oil filter manifold.
Is pressure difference noticeably lower than approximately 15 200 kPa (152 bar) (2200 psi)?
Result:

NO:Go to Fan Speed Check.
Action:
Remove hydraulic fan speed solenoid. Inspect for any debris that would prevent normal solenoid operation.
Is fan speed solenoid free of debris?
Result:

NO:Clean fan speed solenoid. Install and check fan operation.
Action:
Check hydraulic fan motor case drain leakage. See Hydraulic Fan Motor Case Drain Test . (Group 9025-25.)
Is hydraulic motor case drain below maximum specification?
Result:

NO:Repair or replace hydraulic fan motor. See Fan Drive Motor Remove and Install . (Group 3160.)
Action:
Check hydraulic charge pump flow. See Charge Pump Flow Test . (Group 9025-25.)
Result:
YES:Go to Fan Speed Check.

( 6 ) Fan Speed Check (Operating Temperature)
Action:
→NOTE:
Rear grille must be installed for accurate fan speed measurement. Fan speed can be slower by 100—200
rpm when rear grille is not installed.
Check fan speed at fast idle with machine at operating temperature. See Hydraulic Fan Motor Speed Test . (Group 9025-25.)
Is fan speed within specification at fast idle?
Result:
YES:Checks complete. Charge system functioning correctly. If problems continue, check main hydraulic system pressure with
no functions active at fast idle. Pressure should be approximately 1380—2070 kPa (14—21 bar) (200—300 psi). If pressure is
higher, determine cause of high hydraulic system pressure.
Action:
Is fan speed solenoid free of debris?
Result:

NO:Clean fan speed solenoid. Install and check fan operation.
Action:
Check hydraulic fan motor case drain leakage. See Hydraulic Fan Motor Case Drain Test . (Group 9025-25.)
Is hydraulic motor case drain below maximum specification?
Section 9025 - HYDRAULIC SYSTEM Group 25: Tests
Result:
YES:Check hydraulic charge pump flow. See Charge Pump Flow Test . (Group 9025-25.) If charge pump flow is not within
specification, Repair or replace charge pump. See Charge Pump Remove and Install . (Group 3160.)
NO:Repair or replace hydraulic fan motor. See Fan Drive Motor Remove and Install . (Group 3160.)
Hydraulic Fan Will Not Reverse Direction
73
Hydraulic Fan Will Not Reverse Direction Diagnostic Procedure

Action:
Result:

NO:Go to Hydraulic Fan Reversing Solenoids Check.
( 2 ) Hydraulic Fan Reversing Solenoids Check
Action:
Check hydraulic fan reversing solenoids, ensure that resistance is within specification and solenoid valves are operating
properly. See Hydraulic Fan Operation . (Group 9025-05.) See Solenoid Test . (Group 9015-20.)
Are hydraulic fan reversing solenoids operating properly?
Result:
YES:Go to Reversing Fan Valve.

NO:Clean, repair, or replace hydraulic fan reversing solenoids.
( 3 ) Reversing Fan Valve
Action:
Inspect reversing fan valve for proper operation. See Hydraulic Fan Operation . (Group 9025-05.)
Is reversing fan valve operating properly?
Result:
NO:Clean, repair, or replace reversing fan valve.
Group 25 - Tests
JT05800 Digital Thermometer Installation
LEGEND:
A Temperature Probe
B Cable
C JT05800 Digital Thermometer
JT05800 Digital Thermometer
JT05800 Digital Thermometer
[1] - Fasten temperature probe (A) to a bare metal hydraulic line using a tie band.
Digital Thermometer
JT05800
To measure the temperature of hydraulic oil.
[2] - Wrap temperature probe and line with a shop towel.
JT02156A Digital Pressure/Temperature Analyzer Installation
JT02156A Digital Pressure/Temperature Analyzer

LEGEND:
A Digital Pressure/Temperature Analyzer
B 3 400 kPa (35 bar) (500 psi) Transducer
34 000 kPa (350 bar) (5000 psi) Transducer
70 000 kPa (700 bar) (10,000 psi) Transducer
JT02159 20 ft Cable with Couplers
JT02161 500 psi Transducer
JT05969 Thermo-Coupler
312883 Carry Case
JT02160 10,000 psi Transducer (Optional, Order Separately)
JT07148-2 Flow Block
Use the digital pressure/temperature analyzer (A), and transducers (B) in place of analog gauges and a separate temperature
reader.
Digital Pressure/Temperature Analyzer
JT02156A
Kit contains the analyzer, cable, two transducers, thermocouple, and a carry case.
20 ft Cable with Couplers
JT02159
To connect transducer to digital pressure/temperature analyzer.
500 psi Transducer
JT02161
To measure hydraulic oil pressure and vacuum.
5000 psi Transducer
JT02162
To measure hydraulic oil pressure.
Thermo-Coupler
JT05969
To measure hydraulic oil temperature.
Carry Case
312883
Storage for analyzer and components.
10,000 psi Transducer (Optional, Order Separately)
JT02160
Flow Block
JT07148-2
To be used with digital pressure/temperature analyzer to measure flow and pressure.
Transducers are temperature sensitive. Allow transducer to warm to system temperature. After transducer is warmed and no
pressure applied, push sensor zero button for one second to set the true zero point.
When using for different pressures, turn selector to OFF for two seconds and then to the pressure range. Readings are
inaccurate if proper range for transducer is not used.
Remote Start Box Installation

JT0KV12444 Remote Start Box or JT0KV12444A Remote Start Box
The remote start box allows the engine to be started with the cab raised and in the locked position.
[2] -
CAUTION:
Avoid possible injury from moving tires when using remote start box. Keep tire area clear of bystanders.
Do not use remote start box without raising and blocking skid steer loader. Skid steer loader may
override brake and move quickly.
Raise and block machine. See Raising and Blocking Machine . (Operator′s Manual.)
[3] - Raise operator′s station. See Raising Operator′s Station . (Operator′s Manual.)
[4] -
→NOTE:
If using JT0KV12444 Remote Start Box (without engine speed control dial), engine speed control dial (3)
and service engine speed control 3-pin connector (X9) can be used to control engine speed with
operator’s station raised. See Engine Speed Control for Testing . (Group 9026-25.)
LEGEND:
1 Right Frame
2 JT0KV12444 Remote Start Box
3 Engine Speed Control Dial
Remote Start Box Installation

Connect JT0KV12444 Remote Start Box (2) or JT0KV12444A Remote Start Box 4-pin connector to remote start box 4-pin
connector (X10) inside right frame (1).
Remote Start Box
JT0KV12444
Lets the technician start a the engine without sitting in the seat of the machine, allowing service and diagnostics with the
operator′s station in the raised position.
[5] - If connecting JT0KV12444A Remote Start Box, connect the 3-pin connector from remote start box to service engine speed
control 3-pin connector (X9).
[6] -
CAUTION:
Prevent personal injury, do not operate boom and bucket functions when using remote start box. Boom
and bucket hydraulics are enabled when engine is running and park brake switch is disengaged by the
remote start box.
Use remote start box to:
Start and stop engine with cab raised and in locked position.
Engage and disengage park brake with cab raised and in locked position (manual control machines only).
Control engine speed with cab raised and in locked position (JT0KV12444A Remote Start Box only).
[7] - Remove remote start box.
[8] - Lower operator′s station.
[9] - Clear engagement and monitor unit (EMU) diagnostic trouble code 522379.06, if necessary. See Reading Diagnostic
Trouble Codes (DTCs) . (Group 9015-20.)
→NOTE:
Using the remote start box may generate diagnostic trouble code 522379.06. If the remote start box has
been used, clear the code and operate the machine. Recheck codes to verify code has been cleared.
Hydraulic System Pressure Release
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system
before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying
pressure.
This procedure is to relieve trapped hydraulic system pressure before performing hydraulic system repairs or tests.
[1] - Sit in seat. Close cab door if equipped.
[2] - Lower interlocking seat bar. See Interlocking Seat Bar . (Operator′s Manual.)
[3] - Turn key to run position. Do not start engine.
[4] - Switch park brake switch to middle position to engage hydraulic functions.
[5] - Raise and then lower interlocking seat bar.
[6] -
LEGEND:
1 Access Cover
Boom Release Handle Access Cover

Remove access cover (1).
[7] -
LEGEND:
123 Boom Release Handle
Boom Release Handle

Pull up on boom release handle (123) and hold.
[8] -
CAUTION:
To prevent crushing injury, only perform hydraulic system pressure release with boom down or boom up
with boom lock engaged. To lower boom manually, see Boom Release . (Operator′s Manual.)
Cycle both the boom and bucket functions.
[9] - Stop cycling functions once pressure has been released.
[10] - Cycle auxiliary hydraulics function.
[11] - Stop cycling auxiliary hydraulics function once pressure has been released.
[12] - Engage park brake and turn key switch to off.
Boom Release Cable Adjustment

The boom release cable provides a means to shift the port lock spool when there is no hydraulic pressure available.
[3] -
Boom Release Cable Adjustment

LEGEND:
1 Boom Release Cable Mounting Bracket
2 Boom Release Cable Adjusting Nut (2 used)
3 Boom Release Cable
98 Port Lock Spool
Remove footwell to gain access to the boom release cable mounting bracket (1). See Footwell Removal . (Operator′s Manual.)
[4] - Loosen both boom release cable adjusting nuts (2) at boom release cable mounting bracket.
[5] - Push boom release handle (123) in completely.
[6] - Adjust boom release cable adjusting nuts so there is no play in the boom release cable (3). Tighten boom release cable
adjusting nuts.
[7] - Install footwell and lower operator′s station.
Pilot Control Accumulator Precharge Test

Specifications
SPECIFICATIONS
43°C
110°F
1100 kPa
Pilot Control Accumulator Precharge Pressure (approximate) 10 bar
160 psi
Tee (-6 M ORFS x -6 F ORFS x -6 M ORFS)
Quick Coupler (-6 ORFS)
JT02161 Transducer 3400 kPa (35 bar) (500 psi)
Gauge 3400 kPa (35 bar) (500 psi)
The pilot control accumulator is used to provide pressure to the control valve so the pressure in the auxiliary hydraulics can be
released when the engine is off.
[1] - Ensure that charge oil pressure is correct. Perform Charge Pressure Relief Valve Test . (Group 9025-25.)
[3] -
CAUTION:
pressure.
Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure Release . (Group 9025-25.)
[5] -
→NOTE:
The pilot control accumulator is located under the footwell to the right of the hydraulic control valve.
Remove footwell to gain access to the pilot control accumulator. See Footwell Removal . (Operator′s Manual.) For pilot control
accumulator location, see Hydraulic System Component Location . (Group 9025-15.)
[6] -
LEGEND:
1 Hose
2 Quick Coupler (-6 ORFS)
3 Tee (-6 M ORFS x -6 F ORFS x -6 M ORFS)
4 Fitting
Pilot Control Accumulator Precharge Test

Remove hose (1) from fitting (4).
[7] - Install a -6 M ORFS x -6 F ORFS x -6 M ORFS tee (3) between hose and fitting.
Tee (-6 M ORFS x -6 F ORFS x -6 M ORFS)
Used to create a test port in the pilot control accumulator circuit.
[8] - Install a -6 ORFS quick coupler (2) to tee.

Used to make a test point for the transducer.
[9] - Install JT02156A Digital Pressure/Temperature Analyzer and JT02161 Transducer or 3400 kPa (35 bar) (500 psi) gauge to
tee. See JT02156A Digital Pressure/Temperature Analyzer Installation . (Group 9025-25.)
Transducer 3400 kPa (35 bar) (500 psi)
JT02161
Used to measure hydraulic pressure.
JT02156A
To display hydraulic pressure readings.
[10] - Lower operator′s station.
[11] -
CAUTION:
Prevent possible injury when entering the machine. Enter the machine carefully. Footwell is not in place
to stand on.
Warm hydraulic oil to specification.

110°F
[12] - Stop engine.
[16] - Observe pressure reading while slowly cycling auxiliary proportional switch in both directions. Charge pressure drops
slowly while cycling switch. The last pressure seen before pressure drop of about 345 kPa (3.4 bar) (50 psi) is hydraulic
accumulator precharge pressure.
[17] - Compare hydraulic accumulator precharge pressure to specification.

Pilot Control Accumulator Precharge Pressure (approximate) 1100 kPa
10 bar
160 psi
[18] -
→NOTE:
Do this test several times to get a “feel” for how to move switch and find pilot control accumulator
precharge.
If pressure is not at specification, replace pilot control accumulator.
Port Lock Solenoid Valve and Port Lock Spool Test

This test is to ensure that the port lock solenoid valve and port lock spool are functioning properly.
→NOTE:
For more information on the interlock logic, see Engagement and Monitor Unit (EMU) Circuit Theory of
[3] - Start engine.
[4] - Move park brake switch to run position.
[5] - Operate boom and bucket controls. The boom and bucket must move freely.
[6] - Return controls to their neutral position and raise interlocking seat bar. The boom and bucket controls must lock as soon
as the interlocking seat bar is raised.
[7] - If function is not correct, check the port lock solenoid electrical circuit. See Solenoid Test . (Group 9015-20.)
[8] - If port lock solenoid electrical circuit is good, check boom and bucket spool lock solenoids. See Boom and Bucket Spool
Lock Solenoid Test . (Group 9025-25.)
[9] - If both electrical circuits are good, check port lock spool. See Control Valve Disassemble and Assemble . (Group 3160.)
Boom and Bucket Spool Lock Solenoid Test

This test is to ensure that the boom and bucket spool lock solenoids are functioning properly.
→NOTE:
For more information on the interlock logic, see Engagement and Monitor Unit (EMU) Circuit Theory of
[5] - Move boom and bucket controls. Controls should move freely.
[6] - Return controls to their neutral position and raise interlocking seat bar. The boom and bucket controls should lock as soon
as the interlocking seat bar is raised.
[7] - If function is not correct, check the boom and bucket spool lock solenoids and electrical circuit. See Solenoid Test . (Group
9015-20.)
[8] - If boom and bucket spool lock solenoid electrical circuit is good, check boom and bucket solenoid lockout pins and valve
spools. See Control Valve Disassemble and Assemble . (Group 3160.)
Hydraulic System Relief Valve Test

Specifications
SPECIFICATIONS
43°C
Hydraulic Oil Temperature (minimum)
110°F
23 800—24 500 kPa

Hydraulic System Relief Valve Pressure 238—245 bar
3450—3550 psi
JT02158 Digital Pressure and Temperature Analyzer
JT02162 34 000 kPa (350 bar) (5000 psi) Transducer
Auxiliary Quick Coupler (female)
Adapter Fittings (as needed)
Diagnostic Quick Coupler
This test is to ensure that the hydraulic system relief valve is working properly to protect the hydraulic system from excessive
pressures.
[1] - Remove front attachment and park machine on flat, level surface.
[2] -
CAUTION:
pressure.
[3] - Connect auxiliary quick coupler, adapter fittings (as needed), and diagnostic quick coupler to male auxiliary port (118).
LEGEND:
Auxiliary Couplers
Digital Pressure and Temperature Analyzer

JT02158
To display digital readings for temperature and single, multiple, or differential hydraulic oil pressure. Also reads vacuum when
used with 500 psi transducer.
34 000 kPa (350 bar) (5000 psi) Transducer
JT02162
Auxiliary Quick Coupler (female)
Used to attach transducer to auxiliary port.

Adapter Fittings (as needed)
Diagnostic Quick Coupler
[4] -
→NOTE:
Male auxiliary hydraulic connector is pressure port.
Connect JT02158 Digital Pressure Analyzer with JT02162 35 000 kPa (350 bar) (5000 psi) Transducer to diagnostic quick
coupler.
[5] - Start engine and warm hydraulic oil to specification.

Hydraulic Oil Temperature (minimum) 43°C
110°F
[6] - If equipped, ensure that high flow hydraulics are not activated.
[7] - Set engine speed to specification.

[8] - Operate auxiliary function to supply hydraulic flow to the male auxiliary port. See Operating Auxiliary Hydraulics .
Pressure in auxiliary circuit will open system relief valve. Record pressure reading when system relief valve opens.
[9] - Compare system relief valve pressure reading to specification.

Hydraulic System Relief Valve Pressure 23 800—24 500 kPa
238—245 bar
3450—3550 psi
[10] -
→NOTE:
Hydraulic system relief valve is located in the hydraulic control valve. See Hydraulic System Component
LEGEND:
7 Adjusting Screw
8 Lock Nut
Hydraulic System Relief Valve (manual controls shown,

EH controls similar)
If hydraulic system relief pressure is not correct, adjust hydraulic system relief valve (76).
a. Remove footwell to gain access to the hydraulic control valve (75). See Footwell Removal . (Operator′s Manual.)
b. Loosen lock nut (8).
→NOTE:
Turn adjustment screw clockwise to increase pressure and counterclockwise to decrease pressure.
Turn adjusting screw (7) to set relief pressure.
d. Hold adjusting screw in place while tightening lock nut.
[11] - If hydraulic system relief pressure can not be attained, replace hydraulic system relief valve. See Control Valve
Disassemble and Assemble . (Group 3160.)
Charge Pressure Relief Valve Test

Specifications
SPECIFICATIONS
43°C
110°F
2200 kPa
Charge Relief Pressure (minimum) 22 bar
320 psi
JT02161 Transducer 3400 kPa (35 bar) (500 psi)
Gauge 3 400 kPa (35 bar) (500 psi)
This test is performed to ensure that there is sufficient oil pressure to charge the hydrostatic system and supply oil to the
hydraulic system.
[2] -
CAUTION:
pressure.
[3] - Remove right engine side panel to gain access to the hydraulic oil filter manifold. See Engine Side Panels—Remove and
Install . (Operator′s Manual.)
[4] -
LEGEND:
1 JT02161 Transducer 3400 kPa (35 bar) (500 psi)
2 JT02156A Digital Pressure/Temperature Analyzer
Charge Pressure Relief Test

Install JT02156A Digital Pressure/Temperature Analyzer and JT02161 Transducer or 3400 kPa (35 bar) (500 psi) gauge to
hydraulic oil test port (50). See JT02156A Digital Pressure/Temperature Analyzer Installation . (Group 9025-25.)
Transducer 3400 kPa (35 bar) (500 psi)

JT02161
JT02156A
Gauge 3 400 kPa (35 bar) (500 psi)
[5] - Warm hydraulic oil to specification.

110°F

[7] - Record pressure reading. Compare reading to specification.

Charge Relief Pressure (minimum) 2200 kPa
22 bar
320 psi
[8] - If charge relief pressure does not meet specification:
Verify that fan bypass valves are functioning properly (if equipped). See solenoid valve diagnostics in Engine Hard to Start
or Does Not Start When Cold . (Group 9010-15.)
[9] - If fan bypass valves are functioning properly and charge pump flow meets specification, replace charge pressure relief
valve.
Circuit Relief Valve Test

Specifications
SPECIFICATIONS
23 800—25 200 kPa

Boom Up Relief Valve Pressure 238—252 bar
3450—3650 psi
23 800—25 200 kPa

Bucket Dump Relief Valve Pressure 238—252 bar
3450—3650 psi
28 800—30 200 kPa

Bucket Curl Relief Valve Pressure 288—302 bar
4180—4380 psi
JT07192 Electric/Hydraulic Pump
Cap (-10 ORFS) (2 used)
Plug (-10 ORFS)
Cap (-8 ORFS)
Plug (-8 ORFS) (2 used)
These tests are performed to check boom and bucket circuit relief valves. The circuit relief valves are isolated in the hydraulic
control valve. An electric/hydraulic pump is used to apply pressure to the circuit relief valves.
Boom Up Circuit Relief Test
→NOTE:
Test is described using right boom up line at test port. Left boom up line may be used if needed.
[2] - Lock boom in raised position. See Boom Lock . (Operator′s Manual.)
[3] -
CAUTION:
pressure.
[4] -
LEGEND:
1 Left Boom Up Line
2 Plug (-10 ORFS)
3 Cap (-10 ORFS)
4 Left Boom Up Hose
106 Boom Cylinder
Boom Up Circuit Relief Valve Test (left side) (328D

shown, other D series machines similar)
Disconnect left boom up hose (4) from left boom up line (1) on left side of machine.
[5] - Install a -10 ORFS cap (3) and -10 ORFS plug (2) on left boom up hose and line.
Cap (-10 ORFS)
Used to cap boom up hose for boom up circuit relief valve test.
Plug (-10 ORFS)
Used to plug boom up line for boom up circuit relief valve test.
[6] -
LEGEND:
5 Right Boom Up Hose
7 Right Boom Up Line
8 Cap (-10 ORFS)
106 Boom Cylinder
Boom Up Circuit Relief Valve Test (right side) (328D

shown, other machines similar)
Disconnect right boom up hose (5) from right boom up line (7) on right side of machine.
[7] - Install a -10 ORFS cap (8) on right boom up hose.

Cap (-10 ORFS)
Used to cap boom up hose for boom up circuit relief valve test.
[8] - Install a -10 ORFS quick coupler (6) on right boom up line.
Used to provide a test port for the boom up circuit relief valve test.
[9] -
LEGEND:
9 JT07192 Electric/Hydraulic Pump
10 Electric/Hydraulic Pump Hose
11 Gauge
Electric/Hydraulic Pump
Connect JT07192 Electric/Hydraulic Pump (9) and electric/hydraulic pump hose (10) to quick coupler on right boom up line.
JT07192
Used to test circuit reliefs.
[10] -
→NOTE:
Port lock spool must be shifted to allow for hydraulic pressure to reach circuit relief valve in hydraulic
control valve. The boom release handle shifts the port lock spool when charge oil pressure is not
available.
LEGEND:
Boom Release Handle

Pull and hold boom release handle (123) while running the pump.
[11] - Start JT07192 Electric/Hydraulic Pump to pressurize the port. Take reading when pressure on gauge (11) begins to
decrease.
[12] - Compare results to specification.

Boom Up Relief Valve Pressure 23 800—25 200 kPa
238—252 bar
3450—3650 psi
[13] -
→NOTE:
Boom up circuit relief valve is not adjustable.
If pressure is not within specification, replace boom up circuit relief valve. See Control Valve Disassemble and Assemble .
(Group 3160.)
Bucket Dump Circuit Relief Test

[2] -
CAUTION:
pressure.
[3] -
Boom Step
LEGEND:
12 Front Cap Screw (2 used)
13 Boom Step
14 Rear Cap Screw (2 used)
Remove front cap screws (12).
[4] - Loosen rear cap screws (14).
[5] - Remove boom step (13) to gain access to bucket plumbing.
[6] -
LEGEND:
15 Bucket Dump Tee
16 Cap (-8 ORFS)
17 Left Bucket Dump Hose
18 Plug (-8 ORFS)
19 Plug (-8 ORFS)
20 Right Bucket Dump Hose
Bucket Dump Circuit Relief Valve Test

Remove left bucket dump hose (17) from bucket dump tee (15).
[7] - Install a -8 ORFS cap (16) on bucket dump tee.

Cap (-8 ORFS)

Used to cap bucket dump tee for bucket dump circuit relief valve test.
[8] - Install a -8 ORFS plug (18) on left bucket dump hose.

Plug (-8 ORFS)
Used to plug left bucket dump hose for bucket dump circuit relief valve test.
[9] - Remove right bucket dump hose (20) from bucket dump tee.
[10] - Install a -8 ORFS plug (19) on right bucket dump hose.

Plug (-8 ORFS)
Used to plug right bucket dump hose for bucket dump circuit relief valve test.
[11] - Install a -8 ORFS quick coupler (21) on bucket dump tee.

Used to provide a test port for the bucket dump circuit relief valve test.
[12] -
LEGEND:
11 Gauge
Connect JT07192 Electric/Hydraulic Pump (9) and electric/hydraulic pump hose (10) to quick coupler on bucket dump tee.
JT07192
decrease.

Bucket Dump Relief Valve Pressure 23 800—25 200 kPa
238—252 bar
3450—3650 psi
[15] -
→NOTE:
Bucket dump circuit relief valve is not adjustable.
If pressure is not within specification, replace bucket dump circuit relief valve. See Control Valve Disassemble and Assemble .
(Group 3160.)
Bucket Curl Circuit Relief Test
[2] -
CAUTION:
pressure.
[3] -
Boom Step
LEGEND:
12 Front Cap Screw (2 used)
13 Boom Step
14 Rear Cap Screw (2 used)
Remove front cap screws (12).
[4] - Loosen rear cap screws (14).
[5] - Remove boom step (13) to gain access to bucket plumbing.
[6] -
LEGEND:
22 Bucket Curl Tee
23 Cap (-8 ORFS)
24 Left Bucket Curl Hose
25 Plug (-8ORFS)
26 Plug (-8ORFS)
27 Right Bucket Curl Hose
Bucket Curl Circuit Relief Valve Test

Remove left bucket curl hose (24) from bucket curl tee (22).
[7] - Install a -8 ORFS cap (23) on bucket curl tee.

Cap (-8 ORFS)
Used to cap bucket curl tee for bucket curl circuit relief valve test.
[8] - Install a -8 ORFS plug (25) on left bucket curl hose.

Plug (-8 ORFS)
Used to plug left bucket curl hose for bucket curl circuit relief valve test.
[9] - Remove right bucket curl hose (27) from bucket curl tee.
[10] - Install a -8 ORFS plug (26) on right bucket curl hose.

Plug (-8 ORFS)
Used to plug right bucket curl hose for bucket curl circuit relief valve test.
[11] - Install a -8 ORFS quick coupler (21) on bucket curl tee.

Used to provide a test port for the bucket curl circuit relief valve test.
[12] -
LEGEND:
11 Gauge
Connect JT07192 Electric/Hydraulic Pump (9) and electric/hydraulic pump hose (10) to quick coupler on bucket curl tee.
JT07192
[13] -
→NOTE:
Port lock spool must be shifted to allow for hydraulic pressure to reach circuit relief valve in hydraulic
control valve. The boom release handle shifts the port lock spool when charge oil pressure is not
available.
LEGEND:
Boom Release Handle

Pull and hold boom release handle (123) while running the pump.
decrease.

Bucket Curl Relief Valve Pressure 28 800—30 200 kPa
288—302 bar
4180—4380 psi
[16] -
→NOTE:
Bucket curl circuit relief valve is not adjustable.
If pressure is not within specification, replace bucket curl circuit relief valve. See Control Valve Disassemble and Assemble .
(Group 3160.)
Function Drift Test

Specifications
SPECIFICATIONS
43°C
110°F
Engine Speed Slow Idle
13 mm/5 min.
Boom Cylinder Drift (maximum)
0.5 in./5 min.
13 mm/5 min.
Bucket Cylinder Drift (maximum)
0.5 in./5 min.
Boom Down Drift Check
→NOTE:
These checks will require two people if machine is equipped with cab door.
Machine must be equipped with a bucket (empty) for these checks.
[1] -
Function Drift Measurement

Close cab door, if equipped.
[2] - Operate hydraulic system until hydraulic oil reaches temperature specification.
110°F
[3] - Actuate boom function to lower boom to ground.
[4] - Raise boom half way.
[5] - Engage park brake.
[6] - Mark and record a distance on the boom cylinder rod from the cylinder barrel.
[7] - Disengage park brake.
[8] - Allow machine to sit with engine speed at slow idle for 5 minutes.
[10] - Measure marked distance on boom cylinder rod.
0.5 in./5 min.
[11] - If boom drift down is more than specification, continue with the following steps.
[14] - Turn engine off.
[15] - Allow machine to sit for 5 minutes.

0.5 in./5 min.
[17] - If boom drift down is more than specification, diagnose cause of boom drift. See Boom Drifts Down . (Group 9025-15.)
Boom Up Drift Check
→NOTE:
[1] -

110°F
[3] -
→NOTE:
Bucket may need to be in dump position.
[5] - Mark and record a distance on the boom cylinder rod from the cylinder barrel.

0.5 in./5 min.
[10] - If boom drift up is more than specification, continue with the following steps.
[11] - Actuate boom down function to raise front of machine off of the ground.

0.5 in./5 min.
[15] - If boom drift up is more than specification, diagnose cause of boom drift. See Boom Drifts Up . (Group 9025-15.)
Bucket Dump Drift Check
→NOTE:
[1] -

110°F
[4] - Fully roll back bucket.
[5] - Dump bucket half way.
[7] - Mark and record a distance on the bucket cylinder rod from the cylinder barrel.
[11] - Measure marked distance on bucket cylinder rod.

0.5 in./5 min.
[12] - If bucket dump drift is more than specification, continue with the following steps.
[14] - Fully roll back bucket.

0.5 in./5 min.
[20] - If bucket dump drift is more than specification, diagnose cause of bucket drift. See Bucket Drifts Down . (Group
9025-15.).
Bucket Curl Drift Check
→NOTE:
[1] -

110°F
[6] - Mark and record a distance on the bucket cylinder rod from the cylinder barrel.

0.5 in./5 min.
[11] - If bucket curl drift is more than specification, continue with the following steps.

0.5 in./5 min.
[18] - If bucket curl drift is more than specification, diagnose cause of bucket drift. See Bucket Drifts Up . (Group 9025-15.)
Hydraulic Cylinder Leakage Test

Specifications
SPECIFICATIONS
43°C
110°F
5 mL/min
Hydraulic Cylinder Leakage (maximum)
0.2 oz/min
Measuring Beaker
Hose (as necessary)
[1] - Remove front attachment and park machine on flat, level surface.

110°F
[3] - Put control levers/joysticks in neutral and engage park brake.
[4] - Start engine. Fully retract cylinder rod.
[5] - Stop engine.
[6] -
CAUTION:
Escaping Fluid
pressure.
Release hydraulic system pressure. See Hydraulic System Pressure Release . (Group 9025-25.)
[7] - Disconnect head end hose and install a plug in hose end.
[8] -
→NOTE:
To make sure leakage test is accurate, allow all residual hydraulic oil to drain from cylinder head end
port.
Use a hose to route hydraulic oil to measuring beaker, as necessary.
After hydraulic oil stops dripping from cylinder port, put a measuring beaker under the cylinder port to catch hydraulic oil.
Measuring Beaker
Collect hydraulic oil during cylinder leakage test.
Hose (if necessary)
Route hydraulic oil from cylinder to measuring beaker.
[9] - Start engine and run to specification.

[10] - Actuate the cylinder retract function for one minute.
[11] - Stop engine. Measure hydraulic oil collected and connect hose.
Hydraulic Cylinder Leakage (maximum) 5 mL/min
0.2 oz/min
[12] - If measured hydraulic oil is not within specification, repair cylinder as necessary. (See Group 3160 in Repair Manual.)
[13] - Repeat procedure to test each cylinder.
Hydraulic Pump Flow Test

Perform a pump flow test to ensure that the hydraulic pump is delivering sufficient oil flow to operate the hydraulic system.
Pump flow can be tested in two ways, by either connecting flowmeter directly to hydraulic pump output, or by connecting
flowmeter to machine auxiliary couplers.
Connecting flowmeter directly to pump output bypasses the control valve, which yields a more accurate test of pump flow.
High flow pump output can only be tested by connecting flowmeter to machine auxiliary connectors.
This test is performed to ensure that the hydraulic pump is delivering sufficient oil flow to operate the hydraulic system.
Hydraulic Pump Flow Test—Direct Pump Connection
Specifications
SPECIFICATIONS
43°C
110°F
13 800 kPa
Flow Rate Test Pressure 138 bar
2000 psi
329D Pump Flow
79 L/min.
Hydraulic Pump Flow Rate (typical, new)
21 gpm
64 L/min.
Hydraulic Pump Flow Rate (minimum)
16.8 gpm
333D Pump Flow
95 L/min.
25 gpm
76 L/min.
20.2 gpm
JT07148 Digital Hydraulic Flowmeter
Test Hose
This pump flow test will only test output of main hydraulic pump, even if machine is equipped with high flow option.
[1] -
LEGEND:
7 Hydraulic Pump Pressure Hose (to control valve)
43 Hydraulic Pump
Hydraulic Pump Connections (318D EH machine shown)

Remove front attachment and park machine on flat level surface.
[2] -
CAUTION:
pressure.
[3] - Raise operator’s station. See Raising Operator’s Station . (Operator’s Manual.)
[4] - Remove footwell to gain access to the hydraulic pump (43). See Footwell Removal . (Operator’s Manual.)
[5] - Remove hydraulic pump pressure hose (7) from hydraulic pump outlet port.
[6] -
LEGEND:
3 Test Hose
5 Digital Hydraulic Flowmeter Manifold
6 Loading Valve
7 Hydraulic Pump Pressure Hose (to control valve)
43 Hydraulic Pump
Hydraulic Pump Test Connections (318D EH machine

shown)
Connect test hose (3) from hydraulic pump outlet port to inlet port on digital hydraulic flowmeter manifold (5).
Digital Hydraulic Flowmeter
JT07148
Used to record hydraulic oil flow from main hydraulic pump.
Test Hose
Used to attach digital hydraulic flowmeter to hydraulic pump.
[7] - Connect hydraulic pump pressure hose to outlet port of flowmeter manifold. Outlet flow from flowmeter should go to
control valve.
[8] - Connect digital hydraulic tester and digital hydraulic tester harness to flowmeter manifold.
[9] - Lower operator’s station.
[10] - Check that the loading valve of flowmeter is open.

110°F

[13] - Set loading valve to flow rate test pressure.
Flow Rate Test Pressure 13 800 kPa
138 bar
2000 psi
[14] - Read and record flow rate. Compare reading to specification.

329D Pump Flow

Hydraulic Pump Flow Rate (typical, new) 79 L/min.
21 gpm
Hydraulic Pump Flow Rate (minimum) 64 L/min.
16.8 gpm
333D Pump Flow

25 gpm
20.2 gpm
[15] - If flow does not meet specification, check diagnostic trouble codes. See Reading Diagnostic Trouble Codes (DTCs) .
(Group 9015-20.)
[16] - If flow is still low, rebuild or replace hydraulic pump. See Hydraulic Pump Remove and Install and see Hydraulic Pump
Hydraulic Pump Flow Test—Auxiliary Coupler Connection
Specifications
SPECIFICATIONS
43°C
110°F
13 800 kPa
Flow Rate Test Pressure 138 bar
2000 psi
329D Pump Flow
79 L/min.
21 gpm
64 L/min.
16.8 gpm
132 L/min.
Hydraulic Pump (with high flow) Flow Rate (typical, new)
35 gpm
107 L/min.
Hydraulic Pump (with high flow) Flow Rate (minimum)
28.3 gpm
333D Pump Flow
95 L/min.
25 gpm
76 L/min.
20.2 gpm
129 L/min.
Hydraulic Pump (with high flow) Flow Rate (typical, new)
34 gpm
104 L/min.
Hydraulic Pump (with high flow) Flow Rate (minimum)
27.6 gpm
JT07148 Digital Hydraulic Flowmeter
Auxiliary Quick Couplers
Test Hose (2 used)
This pump flow test will test output from both main hydraulic pump and high flow pump if machine is equipped with high flow
option.
[2] -
CAUTION:
pressure.
[3] - Connect test hoses (3) to auxiliary ports (115 and 118).
LEGEND:
1 Digital Hydraulic Tester
2 Quick Coupler (2 used)
3 Test Hose (2 used)
4 Digital Hydraulic Tester Harness
5 Digital Hydraulic Tester Manifold
6 Loading Valve
Digital Hydraulic Flowmeter Tester
Auxiliary Couplers
Digital Hydraulic Flowmeter

JT07148
Used to record hydraulic oil flow from main hydraulic pump.
Auxiliary Quick Couplers
Used to attach test hoses to auxiliary ports.
Test Hose (2 used)
Used to attach digital hydraulic flowmeter to auxiliary couplers.
[4] -
→NOTE:
Male auxiliary hydraulic connector is pressure port.
Connect digital hydraulic tester manifold (5) to test hoses.
[5] - Connect digital hydraulic tester (1) and digital hydraulic tester harness (4) to digital hydraulic tester manifold.
[6] - Check that the loading valve (6) is open.

110°F

[9] - Set auxiliary hydraulic flow to the male auxiliary port. See Operating Auxiliary Hydraulics . (Operator′s Manual.)
[10] - Set loading valve to flow rate test pressure.

Flow Rate Test Pressure 13 800 kPa
138 bar
2000 psi
[11] - Read and record flow rate. Compare reading to specification.

329D Pump Flow

21 gpm
16.8 gpm
Hydraulic Pump (with high flow) Flow Rate (typical, new) 132 L/min.
35 gpm
Hydraulic Pump (with high flow) Flow Rate (minimum) 107 L/min.
28.3 gpm
333D Pump Flow

25 gpm
20.2 gpm
Hydraulic Pump (with high flow) Flow Rate (typical, new) 129 L/min.
34 gpm
Hydraulic Pump (with high flow) Flow Rate (minimum) 104 L/min.
27.6 gpm
[12] - If flow does not meet specification:
Check auxiliary hydraulic control valve spool. See Control Valve Disassemble and Assemble . (Group 3160.)
[13] - If flow is still low, rebuild or replace hydraulic pump. See Hydraulic Pump Remove and Install and see Hydraulic Pump
Charge Pump Flow Test

Specifications
SPECIFICATIONS
43°C
110°F
57 L/min.
329D Charge Pump Flow Rate (new typical)
15 gpm
46 L/min.
329D Charge Pump Flow Rate (used minimum)
12.1 gpm
53 L/min.
333D Charge Pump Flow Rate (new typical)
14 gpm
42 L/min.
333D Charge Pump Flow Rate (used minimum)
11.2 gpm
JT07148 Digital Hydraulic Flowmeter Tester
This test ensures there is sufficient charge oil flow to hydraulic fan, hydrostatic, and hydraulic systems.
[2] -
CAUTION:
pressure.
[4] -
LEGEND:
1 Charge Pump Outlet Hose
2 Charge Pump Outlet Port
46 Charge Pump
Charge Pump Outlet Port

Remove footwell to gain access to the charge pump (46). See Footwell Removal . (Operator′s Manual.)
[5] - Remove charge pump outlet hose (1) from charge pump outlet port (2).
[6] - Connect digital hydraulic flowmeter tester in-line between charge pump outlet port and charge pump outlet hose.
JT07148
Used to record hydraulic oil flow from charge pump.
[7] - Check that the loading valve on digital hydraulic flowmeter tester is open.
[8] - Install remote start box. See Remote Start Box Installation . (Group 9025-25.)

110°F

[11] - Record flow rate on digital hydraulic flowmeter tester.

329D Charge Pump Flow Rate (new typical) 57 L/min.
15 gpm
Flow Rate (used minimum) 46 L/min.
12.1 gpm
333D Charge Pump Flow Rate (new typical) 53 L/min.
14 gpm
Flow Rate (used minimum) 42 L/min.
11.2 gpm
[13] - If flow rate is below specification, repair or replace charge pump. See Charge Pump Remove and Install . (Group 3160.)
Hydraulic Fan Motor Speed Test

Specifications
SPECIFICATIONS
Fan Speed Test—Machine Cold
38°C
Hydraulic Oil Temperature (maximum for machine cold test)
100°F
38°C
Engine Coolant Temperature (maximum for machine cold test)
100°F
38°C
Manifold Air Temperature (maximum for machine cold test)
100°F
Hydraulic Fan Speed (maximum with machine cold) 1500 rpm
Fan Speed Test—Operating Temperature
Hydraulic Oil Temperature (operating) 43°C
Hydraulic Oil 110°F
Hydraulic Fan Speed (operating temperature) 2350—2600 rpm
JT05709 Reflective Tape
JT05719 Hand Held Digital Tachometer
The purpose of these tests is to determine that the hydraulic fan is operating correctly, both when machine is cold and at
operating temperature.
Fan Speed Test—Machine Cold
Fan speed above test specification when machine is cold can indicate a malfunction in the hydraulic fan speed solenoid (Y30)
or solenoid circuit.
[1] - Make sure that machine system temperatures are below specifications.
Hydraulic Oil Temperature (maximum for machine cold test) 38°C
100°F
Engine Coolant Temperature (maximum for machine cold test) 38°C
100°F
Manifold Air Temperature (maximum for machine cold test) 38°C
100°F
[2] - Remove engine side panels. See Engine Side Panels—Remove and Install . (Operator′s Manual.)
[3] -
LEGEND:
2 Rear Grille
Rear Grille
Remove cap screws (1) and rear grille (2).
[4] -
LEGEND:
3 JT05709 Reflective Tape
4 Fan Blade
Fan Speed Test

Install JT05709 Reflective Tape (3) to hydraulic fan blade (4).
Reflective Tape
JT05709
Used to measure fan speed.
[5] -
→NOTE:
Install rear grille and cap screws.
[6] - Install engine side panels.

[8] - Record fan speed using JT05719 Hand Held Digital Tachometer.
Hand Held Digital Tachometer
JT05719
[9] - Compare fan speed to specification.

Hydraulic Fan Speed (maximum with machine cold) 1500 rpm
[10] - If fan speed is above maximum specification with machine cold, check the following:
→NOTE: If fan speed solenoid (Y30) is disconnected or circuit is open, fan system will operate at
maximum speed.Fan speed solenoid is located on hydraulic fan motor for non-reversing fans. Fan
speed solenoid is located on reversing fan valve for reversing fans.
Check electrical connections to hydraulic fan speed solenoid (Y30). See Main Harness (W3) Component Location or see
Fan Speed Solenoid Harness (W9) Component Location . (Group 9015-10.)
Fan Speed Test—Operating Temperature
Fan speed not within specification can indicate excessive wear of internal components.
[2] -
LEGEND:
2 Rear Grille
Rear Grille
Remove cap screws (1) and rear grille (2).
[3] -
LEGEND:
3 JT05709 Reflective Tape
4 Fan Blade
Fan Speed Test

Install JT05709 Reflective Tape (3) to hydraulic fan blade (4).
Reflective Tape
JT05709

Hydraulic Oil Temperature (operating) 43°C
110°F
[5] -
→NOTE:
Fan speed solenoid is located on hydraulic fan motor for non-reversing fans. Fan speed solenoid is
located on reversing fan valve for reversing fans. See Hydraulic Fan Operation . (Group 9025-05.)
When fan speed solenoid (Y30) is disconnected, fan system will operate at maximum speed
Disconnect fan speed solenoid.
[6] -
→NOTE:
Install rear grille and cap screws.
[7] - Install engine side panels.

[9] - Record fan speed using JT05719 Hand Held Digital Tachometer.
JT05719
[10] - Compare fan speed to specification.

Hydraulic Fan Speed (operating temperature) 2350—2600 rpm
[11] - If fan speed is not within specification, check the following:
Check fan motor case drain flow. See Hydraulic Fan Motor Case Drain Test . (Group 9025-25.)
[12] - If fan motor case drain and charge pump flows are within specifications, replace fan speed solenoid. For fan speed
solenoid location, See Hydraulic Fan Operation . (Group 9025-05.)
Hydraulic Fan Motor Case Drain Test

Specifications
SPECIFICATIONS
43°C
110°F
500 mL/min.
Hydraulic Fan Motor Case Drain Leakage (maximum)
17 oz./min.
-6 ORFS Plug
Test Hose
Calibrated Container
Stopwatch
The purpose of this test is to determine hydraulic fan motor case drain leakage and compare to specification. Hydraulic fan
motor case drain leakage above specification can indicate excessive wear of internal components.
[2] -
→NOTE:
Case drain plumbing is located under the hydraulic oil cooler.
LEGEND:
2 Case Drain Fitting
3 Case Drain Hose
Hydraulic Fan Motor Case Drain Plumbing

Disconnect case drain hose (3) from case drain fitting (2).
[3] -
LEGEND:
2 Case Drain Fitting
3 Case Drain Hose
4 Plug (-6 ORFS)
5 Test Hose
Hydraulic Fan Motor Case Drain Test

Install a -6 ORFS Plug (4) in case drain hose (3).
Plug
-6 ORFS
Used to plug case drain hose.
[4] - Install test hose (5) to case drain fitting.

Test Hose
Used to provide a means to run case drain oil into a calibrated container.
[5] - Place opposite end of test hose in a calibrated container.

Calibrated Container
Used to measure hydraulic fan motor case drain.

110°F
[7] -
→NOTE:
Fan speed solenoid is located on hydraulic fan motor for non-reversing fans. Fan speed solenoid is
located on reversing fan valve for reversing fans. See Hydraulic Fan Operation . (Group 9025-05.)
Disconnect fan speed solenoid.

[9] - When oil starts to flow from test hose start stopwatch. Run machine for 1 minute after stopwatch has been started.
Stopwatch
Used to time the test.
[10] - Compare case drain leakage to specification.

Hydraulic Fan Motor Case Drain Leakage (maximum) 500 mL/min.
17 oz./min.
[11] - If hydraulic fan motor case drain leakage is above specification, repair or replace hydraulic fan motor. See Fan Drive
Motor Remove and Install . (Group 3160.)
Fan Bypass Valve Test

Specifications
SPECIFICATIONS
1700 kPa
System Charge Pressure (maximum, both fan bypass solenoids energized) 17 bar
250 psi
2100 kPa
System Charge Pressure (minimum, after 5 seconds with solenoids energized) 21 bar
300 psi
2800 kPa
System Charge Pressure (minimum, after 60 seconds with solenoids energized) 28 bar
400 psi
DFT1325 Solenoid Power Harness
This test is performed to ensure that the fan bypass valves that are part of the optional cold start package are functioning
properly. The test requires the engine to start and run.
[2] - Raise and block machine. See Raising and Blocking Machine . (Group 1740.)
[4] -
CAUTION:
pressure.
[5] - Remove right engine side panel to gain access to the hydraulic oil filter manifold. See Engine Side Panels—Remove and
Install . (Operator′s Manual.)
[6] -
LEGEND:
1 JT02162 Transducer 34 000 kPa (350 bar) (5000 psi)
2 JT02156A Digital Pressure/Temperature Analyzer
Fan Bypass Valve Test

Install JT02156A Digital Pressure/Temperature Analyzer and JT02162 Transducer or 7000 kPa (70 bar) (1000 psi) gauge to
hydraulic oil test port (50). See JT02156A Digital Pressure/Temperature Analyzer Installation . (Group 9025-25.)
5000 psi Transducer
JT02162
JT02156A
[8] - Remove footwell. See Footwell Remove and Install . (Group 1910.)
[9] -
CAUTION:
Prevent possible injury from moving tires/tracks when using remote start box. Keep tire/track area clear
of bystanders. Do not use remote start box without raising and blocking machine.
Install remote start box. See Remote Start Box Installation . (Group 9025-25.)
[10] -
LEGEND:
51 Fan Bypass Valve 1
111 Fan Bypass Valve 2
161 Check Tee Fitting
Fan Bypass Valve Test—318D, 319D, 320D and 323D

Machines
Fan Bypass Valve Test—326D, 328D, 329D, 332D, 333D

Machines
Disconnect fan bypass solenoid harness 2-pin connector (X34).
[11] - Install DFT1325 Solenoid Power Harness from battery to connector (X34) to energize fan bypass solenoids. For
instructions on creating harness, see DFT1325 Solenoid Power Harness . (Group 9900-99.)
Solenoid Power Harness
DFT1325
Energize fan bypass solenoids.
[12] - Start engine and run at slow idle.
[13] -
→NOTE:
Hydraulic fan should not be turning.
→NOTE:
Both fan bypass valves are energized and oil flow routed to hydraulic oil tank. Charge oil pressure
regulated by 800 kPa (8 bar) (120 psi) check valve in check tee fitting.
Observe pressure and compare reading to specification.

System Charge Pressure (maximum, both fan bypass solenoids energized) 1700 kPa
17 bar
250 psi
[14] - Disconnect DFT1325 Solenoid Power Harness from connector (X34).
[15] -
→NOTE:
Fan bypass valve 2 closes once power is removed (within 5 seconds). Charge oil pressure regulated by
Observe pressure and compare reading to specification. Within 5 seconds, system charge pressure should be above
specification.
System Charge Pressure (minimum, after 5 seconds with solenoids energized) 2100 kPa
21 bar
HYDROSTATIC SYSTEM (g) by Belgreen v2.0
300 psi
[16] -
→NOTE:
Hydraulic fan may start turning.
→NOTE:
Fan bypass valve 1 closes within 60 seconds after power is removed. Charge oil flow goes through
hydraulic fan, hydraulic oil filter and charge pressure relief valve.
After 60 seconds, system charge pressure should be above specification.

System Charge Pressure (minimum, after 60 seconds with solenoids energized) 2800 kPa
28 bar
400 psi
[17] - Shut off engine.
[18] - Connect fan bypass solenoid harness 2-pin connector (X34).
[19] - If fan bypass valve operation did not match test specifications, check the following:
Check resistance through fan bypass solenoid 1 (Y33) and fan bypass solenoid 2 (Y34). See Electrical Component
Specifications. (Group 9015-20.)
Remove fan bypass valves and inspect for any debris that would prevent normal valve operation.
[20] - Remove remote start box. See Remote Start Box Installation . (Group 9025-25.)
[21] - Install footwell. See Footwell Remove and Install . (Group 1910.)
[22] - Lower operator′s station. See Raising Operator′s Station . (Group 1810.)
[23] - Release boom lock and lower boom.
[24] - Raise machine and remove blocking. See Raising and Blocking Machine . (Group 1740.)
Section 9026 - HYDROSTATIC SYSTEM

Table of contents
Hydrostatic System Operation .............................................................................................................. 1
Hydrostatic Pump Operation ................................................................................................................ 2
Charge Pump Operation ....................................................................................................................... 5
Hydrostatic Motor Operation—Single Speed (S.N. —192141) ............................................................... 7
Hydrostatic Motor Operation—Two Speed (S.N. —192141) .................................................................. 9
Hydrostatic Motor Operation (S.N. 192142— ) ................................................................................... 14
Hydrostatic Control Valve Operation—Single Speed ........................................................................... 18
Hydrostatic Control Valve Operation—Two Speed .............................................................................. 20
Park Brake System Operation ............................................................................................................. 22
Steering Control Operation ................................................................................................................. 23
Group 15 - Diagnostic Information ...................................................................................................... 27
Hydrostatic System Schematic ........................................................................................................... 27
Hydrostatic System Component Location ........................................................................................... 36
Machine Does Not Move In Either Direction Diagnostic Procedure ..................................................... 41
Hydrostatic Pump Or Hydrostatic Motor Noise Diagnostic Procedure ................................................. 43
Slow Response To Changes In Speed Diagnostic Procedure ............................................................... 45
Low Power Diagnostic Procedure ........................................................................................................ 45
Wheels or Tracks Powered On One Side, Not The Other Diagnostic Procedure .................................. 46
Machine Will Not Shift Into Or Out Of High Speed Diagnostic Procedure ............................................ 47
Machine Creeps With Steering Levers In Neutral Diagnostic Procedure ............................................. 49
Hydrostatic System Noise While In Neutral Diagnostic Procedure ...................................................... 51
Steering Levers Hard To Move Diagnostic Procedure ......................................................................... 52
Steering Levers Feel Loose Or ‘Sloppy” Diagnostic Procedure ........................................................... 53
Machine Tracks To One Side With Steering Levers In Full Forward Or Reverse Position Diagnostic
Procedure .................................................................................................................................... 55
Steering Levers Pulse Or Vibrate Excessively Diagnostic Procedure .................................................. 55
Park Brake Does Not Hold Diagnostic Procedure (Single Speed) ........................................................ 57
Park Brakes Do Not Release Diagnostic Procedure (Single Speed) ..................................................... 59
Grinding Noise While Operating Machine Diagnostic Procedure (Single Speed) ................................. 60
Park Brake Does Not Hold Diagnostic Procedure (Two Speed) ........................................................... 62
Park Brakes Do Not Release Diagnostic Procedure (Two Speed) ........................................................ 64
Grinding Noise While Operating Machine Diagnostic Procedure (Two Speed) .................................... 66
Group 25 - Tests ..................................................................................................................................... 67
Engine Speed Control for Testing ....................................................................................................... 67
Hydrostatic Pump System Pressure Relief Test .................................................................................. 69
Track Speed Test ................................................................................................................................ 72
Hydrostatic Pump Flow Test ............................................................................................................... 75
Hydrostatic Pump Neutral Adjustment ............................................................................................... 78
Track Creep Adjustment ..................................................................................................................... 83
Steering Lever Effort Adjustment ....................................................................................................... 86
Centering Assembly Adjustment ........................................................................................................ 87
Steering Lever Adjustment—Centering .............................................................................................. 89
Tracking Adjustment .......................................................................................................................... 91
Hydraulic Control Handle Adjustment—Hands Only Machine ............................................................. 94
Park Brake Release Pressure Test ...................................................................................................... 95

Section 9026 - HYDROSTATIC SYSTEM Group 05: Theory of Operation

Hydrostatic System Operation
The hydrostatic system provides a means to transfer power from the engine to the hydrostatic motors to drive the tracks. It
also provides infinitely variable speed and steering.
The hydrostatic pumps provide oil to the hydrostatic motors through hydrostatic lines and fittings. Oil in the hydrostatic system
circulates in a closed loop circuit. Oil leaves the hydrostatic pumps and flows to the hydrostatic motors and returns to the
hydrostatic pumps. Flushing passages in the hydrostatic motors allow oil to circulate within the closed loop circuit to aid in
cooling of the hydrostatic system components. A charge pump provides a continuous flow of charge oil to the hydrostatic
pumps, park brake spool, and two speed control spool (if equipped).
Steering is controlled by two steering levers located in the operator′s cab. The steering levers control direction (forward and
reverse) and speed (oil flow) of the machine by pivoting the swash plates in the hydrostatic pumps.
For more information, see Hydrostatic System Schematic . (Group 9026-15.)
Hydrostatic Pump Operation
Hydrostatic Pump Port Location (left side)
Hydrostatic Pump Port Location (right side)

LEGEND:
28 Left Forward Pressure Relief Valve
31 Left Reverse Pressure Relief Valve
36 Right Forward Pressure Relief Valve
39 Right Reverse Pressure Relief Valve

44 Hydraulic Pump
46 Charge Pump
131 Left Hydrostatic Motor Forward Port
132 Left Hydrostatic Motor Reverse Port
133 Right Hydrostatic Motor Forward Port
134 Right Hydrostatic Motor Reverse Port
137 Hydrostatic Pump Case Drain Port
138 Hydraulic Oil Tank-to-Charge Pump Port
142 Charge Pressure Port
146 Neutral Adjustment Screw
147 Left Reverse Servo Piston Stop Screw
148 Right Reverse Servo Piston Stop Screw
149 Left Forward Servo Piston Stop Screw
150 Right Forward Servo Piston Stop Screw
151 Right Hydrostatic Pump Charge Pressure Port
152 Left Hydrostatic Pump Charge Pressure Port
153 Charge Pressure Relief Valve
The hydrostatic pumps are tandem mounted, servo controlled, variable displacement, axial piston pumps. The are mounted as
an assembly to the flywheel housing. Power is transferred directly from the engine to the hydrostatic pump assembly by a hub
coupling splined on the hydrostatic pump shaft. The hydrostatic pumps provide oil to the hydrostatic motors through
hydrostatic lines and fittings.
Oil in the hydrostatic system circulates in a closed loop. Oil leaves the hydrostatic pumps and flows to the hydrostatic motors
and returns to the hydrostatic pumps. Oil that leaves this closed loop circuit, such as case drain, is replenished by oil from the
charge pump. For additional line connection information: or
See Hydrostatic Motor Operation—Single Speed (S.N. —192141) . (Group 9026-05.)

See Hydrostatic Motor Operation—Two Speed (S.N. —192141) . (Group 9026-05.)
See Hydrostatic Motor Operation (S.N. 192142— ) . (Group 9026-05.)
Each hydrostatic pump is equipped with two pressure relief valves (28 and 31 for left hydrostatic pump; 36 and 39 for right
hydrostatic pump). The pressure relief valves work in unison with each other. As a pressure relief valve shifts to relieve
excessive pressure, the other pressure relief valve acts as a check valve, allowing oil to flow to the inlet side of the hydrostatic
pump.
Hydrostatic Pump Operation

LEGEND:
1 Servo Piston
2 Summing Link
3 Spool
4 Neutral Adjust Link
5 Neutral Adjust Screw
6 Pin
7 Feedback Link
A cam connects the control lever to the summing link (2). When the control lever is moved, the cam causes the summing link
to pivot on the feedback link (7) and moves the spool (3). Movement of the spool allows oil pressure to flow to one side of the
servo piston (1) causing the piston to move.
The servo piston is connected back to the spool through the feedback link. The feedback link pivots on the neutral adjust link
(4) which is held stationary by the neutral adjust screw (5) and pin (6). The feedback link causes the position of the spool to
vary, depending on load conditions, and results in a constant speed for a given control lever position.
The servo piston is connected to the swash plate through an offset journal located on the swash plate. The servo piston pushes
against the swash plate changing its angle from neutral position.
The position from the center of the swash plate controls the distance the pistons travel inside the piston bore of the rotating
assembly. The direction the swash plate is pivoted from center determines the direction of oil flow (forward or reverse). The
amount of angle the swash plate is deflected determines how much oil will be displaced (speed). See Steering Control
Charge Pump Operation
Charge Pump Location

LEGEND:
44 Hydraulic Pump
46 Charge Pump
138 Hydraulic Oil Tank-to-Charge Pump Port
The charge pump is a fixed displacement, external gear pump. The charge pump is mounted and driven off the end of the
hydraulic pump. The charge pump draws hydraulic oil from the hydraulic oil tank and supplies a constant flow of charge oil to
the hydraulic fan system, hydraulic oil filter manifold, hydrostatic pumps and motors, and hydraulic control valve.
LEGEND:
1 Suction Port
2 Drive Gear
3 Driven Gear
4 Delivery Port
5 Housing
Hydraulic Pump
An external gear pump has two gears in mesh, closely fitted inside a housing (5). A drive shaft drives one gear (drive gear) (2),
which in turn drives the other gear (driven gear) (3).

Hydrostatic Motor Operation—Single Speed (S.N. —192141)

→NOTE:
The single speed hydrostatic motor option is only offered for 329D.
Hydrostatic Motors—329D
LEGEND:
131 Left Forward Hydrostatic Motor Line
132 Left Reverse Hydrostatic Motor Line
133 Right Forward Hydrostatic Motor Line
134 Right Reverse Hydrostatic Motor Line
135 Left Hydrostatic Motor Case Drain Line
136 Right Hydrostatic Motor Case Drain Line
The single speed hydrostatic motor used on the compact track loader is a radial piston motor and planetary gearbox drive
combination with an integral spring applied/hydraulic released park brake. There are two hydrostatic motors on each machine,
mounted outside of the machine frame on either side. Each motor is connected to a park brake assembly bolted to the track
undercarriage. Power from the motor is transmitted through the hydrostatic motor gearbox to the sprocket that powers the
track. The right hand motor drives the right track; the left hand motor drives the left track.
Single Speed Operation

LEGEND:
1 Cam
2 Carrier
3 Manifold
4 Piston Follower
5 Piston
6 Output Shaft
10 Pressure Oil
11 Return Oil
A radial piston motor consists of a cam (1), a carrier (2) with pistons (5), piston followers (4) and a manifold (3). The cam is
attached to the motor housing and the carrier to the output shaft (6). Pressurized oil (10) is routed to the manifold. The oil is
then fed through passages in the carrier to the piston bores. Each passage in the manifold is timed to one cam ramp.
The power stroke is developed when pressurized oil flows through the manifold and carrier oil passages, forcing the pistons
outward. As the piston follower is forced against the cam ramp, the carrier and shaft are forced to turn. Return oil (11) is routed
from the piston bores, through the carrier passages and into the manifold return passages. The oil manifold is spring loaded
against the piston carrier with a thin film of oil separating them.
When the motor is engaged, some pistons are in power stroke, some pistons are in return stroke and some pistons are in
transition between oil passages. As one group of pistons ends its power stroke, another group has begun. This overlapping of
strokes provides smooth power (torque) to the drive shaft, gearbox and tracks.
For more information see:
See Hydrostatic Pump Operation . (Group 9026-05.)

See Hydrostatic Control Valve Operation—Single Speed . (Group 9026-05.)
See Hydrostatic System Schematic . (Group 9026-15.)
Hydrostatic Motor Operation—Two Speed (S.N. —192141)
Hydrostatic Motors—Two Speed

LEGEND:
131 Left Forward Hydrostatic Motor Line
132 Left Reverse Hydrostatic Motor Line
133 Right Forward Hydrostatic Motor Line
134 Right Reverse Hydrostatic Motor Line
135 Left Hydrostatic Motor Case Drain Line
136 Right Hydrostatic Motor Case Drain Line
154 Two Speed Charge Pressure Line
The two speed hydrostatic motor is a radial piston motor. There are two hydrostatic motors on each machine. They are
mounted on the brake assemblies located on the left and right chain cases. The motor driveshaft drives a sprocket and chain
system which transfers power to the wheels. The right hand motor drives the right wheels; the left hand motor drives the left
wheels.
Single Speed Operation

LEGEND:
1 Cam
2 Carrier
3 Manifold
4 Piston Follower
5 Piston
6 Output Shaft
10 Pressure Oil
11 Return Oil
65 Speed Shift Spool
Single Speed Operation— A radial piston motor consists of a cam (1), a carrier (2) with pistons (5), piston followers (4) and a
manifold (3). The cam is attached to the motor housing and the carrier to the output shaft (6). Pressurized oil (10) is routed to
the manifold. It is then fed through passages in the carrier to the piston bores. Each passage in the manifold is timed to one
cam ramp.
The power stroke is developed when pressurized oil flows through the manifold and carrier oil passages, forcing the pistons
outward. As the piston follower is forced against the cam ramp, the carrier and shaft are forced to turn. Return oil (11) is routed
from the piston bores, through the carrier passages and into the manifold return passages. The oil manifold is spring loaded
against the piston carrier with a thin film of oil separating them.
When the motor is engaged, some pistons are in power stroke, some pistons are in return stroke and some pistons are in
transition between oil passages. As one group of pistons ends its power stroke, another group has begun. This overlapping of
strokes provides smooth power (torque) to the axle.
When shifting between speeds, the speed shift spool (65) allows for smooth shifting by reducing shock on the hydrostatic
system.
During single speed operation, the hydrostatic pumps supply pressure oil (10) to each of the piston bores of the hydrostatic
motors. The machine will operate in a slow speed, high torque mode.
Two Speed Operation

LEGEND:
1 Cam
2 Carrier
3 Manifold
4 Piston Follower
5 Piston
6 Driveshaft
10 Pressure Oil
11 Return Oil
65 Speed Shift Spool
Two Speed Operation— When the two speed switch is pressed, the two speed proportional solenoid valve shifts allowing
charge pressure oil (12) to flow to the hydrostatic motors. Charge pressure oil shifts the speed shift spool (65) and speed
selector valve. Charge pressure oil is then routed to half of the piston bores. The pistons in these bores are held out against the
cam and prevent supply pressure oil from entering. Supply pressure oil enters the remaining piston bores. The same volume of
supply pressure oil is routed through the motor but with fewer power strokes. This causes the machine to operate in a high
speed, low torque mode.
For more information:

See Hydrostatic Control Valve Operation—Two Speed . (Group 9026-05.)
Hydrostatic Motor Operation (S.N. 192142— )
Hydrostatic Motor Components

LEGEND:
1 Motor End Cover
2 Valve Plate
3 Rotating Group
4 Speed Ring
5 Swash Plate
6 Swash Plate Bearing (2 used)
7 Shaft
8 Bias Piston
9 Bias Spring
10 Bias Piston-to-Swash Plate Connection
11 Hydrostatic Motor Closed-Loop Shuttle Spool
12 Hydrostatic Motor Relief Valve
13 Motor Speed Sensor Mounting Location
14 Bearing
15 Bearing
16 Park Brake Housing
The hydrostatic motor used on tracked machines is an axial piston motor and planetary gearbox drive combination with an
integral spring applied/hydraulically released park brake. There are two hydrostatic motors on each machine, mounted outside
of the machine frame on either side. Power from the motor is transmitted through the hydrostatic motor gearbox to the
sprocket that powers the track. The right hand motor drives the right track; the left hand motor drives the left track.
LEGEND:
A Port A (supply oil in/out)
B Port B (supply oil in/out)
L1 Port L1 (case drain)
L2 L2 (case drain)
X1 Port X1 (two speed operation)
X2 Port X2 (two speed operation)
XB Port XB (park brake release pressure)
Hydrostatic Motor Port Connections

Supply oil from the corresponding hydrostatic pump enters in either port A or port B in the motor end cover, depending on
direction of travel.
LEGEND:
17 Piston (9 used)
18 Slipper (9 used)
19 Slipper Retainer
20 Cyinder Block
Rotating Group Components

Supply oil flows through the valve plate (2) to half of the pistons (17) in the rotating group (3). The supply oil forces the pistons
against the swash plate (5). The piston slippers (18) slide down the angle face of the swash plate causing the rotating group
and shaft (7) to rotate.
The shaft rotation is transferred to the gearbox moving the machine. Forward or reverse travel direction is determined by
which half of the valve plate ports and pistons are pressurized by supply oil from the pump.
Return oil from the motor exits from either port A or port B in the motor end cover. Case drain oil exits the motor case from
either port L1 or L2, depending on which side of the machine the motor is located.
For additional line connection information, see Hydrostatic Pump Operation . (Group 9026-05.)
Closed-Loop Shuttle Spool and Relief Valve Operation
Hydrostatic Motor Schematic

LEGEND:
8 Bias Piston
11 Hydrostatic Motor Closed-Loop Shuttle Spool
12 Hydrostatic Motor Relief Valve
21 Park Brake
22 Orifice
23 Orifice
24 From Hydrostatic Pump (supply)
25 To Hydrostatic Pump (return)
26 From Hydrostatic Motor (case drain)
27 From Two Speed Solenoid Valve
28 From Park Brake Solenoid Valve
604 Return Oil
611 Charge Oil
When supply oil enters the motor, a portion of the oil is routed to the end of the closed-loop shuttle spool.
The pressure of the oil shifts the spool, opening up a passage for closed-loop return (charge) pressure oil to flow through the
spool.
The closed-loop return (charge) pressure oil passes through the closed-loop shuttle spool to the hydrostatic motor relief valve
(12). The relief valve opens, routing oil through an orifice into the motor case. This case oil is used for cooling the motor during
operation.
Two Speed Operation (If Equipped)
For machines equipped with the two speed option, when the operator selects to shift to high speed, charge pressure oil is sent
from the hydrostatic control valve to either port X1 or port X2 on the motor end cover (depending on which side of machine the
motor is mounted).
Charge pressure oil is routed to the bias piston (8), and overcomes the spring force of the bias spring (9). As the bias piston
moves, the bias piston-to-swash plate connection (10) causes the swash plate to rotate on the swash plate bearings (6). The
swash plate moves to a reduced angle, which reduces the piston travel in the rotating group.
The same volume of supply pressure oil is routed through the motor but the rotating group turns at a higher speed because of
the reduced piston displacement. This causes the machine to operate in a high speed, low torque mode.
Electrohydraulic (EH) Operation (If Equipped)

LEGEND:
4 Speed Ring
13 Motor Speed Sensor Mounting Location
Electrohydraulic (EH) Components

For machines equipped with electrohydraulic (EH) controls, a motor speed sensor is installed in the motor housing at the motor
speed sensor mounting location (13).
The motor speed sensor is used with the speed ring (4) on the cylinder block of the rotating group to provide motor speed
feedback to the hydraulic control unit (HCU).
For machines not equipped with EH controls, a plug is installed in the motor housing. The speed ring is on the cylinder block
but is not used.
Hydrostatic Control Valve Operation—Single Speed
Hydrostatic Control Valve—329D (S.N. —192141)

LEGEND:
142 Charge Pressure Line
151 Right Hydrostatic Pump Charge Pressure Line
152 Left Hydrostatic Pump Charge Pressure Line
156 Park Brake Release Line
157 From Hydraulic Oil Filter Line
Hydrostatic Control Valve—329D (S.N. 192142— )

LEGEND:
160 Charge Pressure Line to Pilot Control Accumulator Manifold
→NOTE:
The single speed hydrostatic motor option is only offered for 329D machines.
The hydrostatic control valve (11) contains the park brake solenoid (Y5). The park brake solenoid controls park brake actuation
by sending charge pressure to release the park brake.
See Park Brake System Operation . (Group 9026-05)

Hydrostatic Control Valve Operation—Two Speed
Hydrostatic Control Valve—Two Speed (S.N. —192141)

LEGEND:
Hydrostatic Control Valve—Two Speed (S.N. 192142—)

LEGEND:
160 Charge Pressure Line to Pilot Control Accumulator Manifold
The hydrostatic control valve (11) contains the park brake solenoid (Y5). The park brake solenoid controls park brake actuation
by sending charge pressure to release the park brake. The hydrostatic control valve contains the charge pressure relief valve
(33).
The two speed solenoid (Y6) controls the two speed drive option. The solenoid is electronically controlled by the two speed
switch mounted on the left steering lever.
When the two speed solenoid is not energized, the solenoid prevents charge oil from flowing to the hydrostatic motors (4 and
16). The machine will operate in a slow speed, high torque mode.
When the two speed solenoid is energized, the solenoid shifts and allows charge oil to flow to the speed shift spool and speed
selector valve in the hydrostatic motors. The machine will operate in a high speed, low torque mode.
If the machine is shut off while in the high speed, low torque mode, the solenoid valve will be de-energized. The machine will
operate in a slow speed, high torque mode when restarted.
See Park Brake System Operation . (Group 9026-05)

Park Brake System Operation

The park brake system is electrically controlled, spring applied and hydraulically released. The machine has a left and a right
park brake assembly located between each hydrostatic motor and the drive axles.
When the park brake switch is engaged (park brake on), the park brake solenoid valve prevents charge pressure oil to flow to
the brake disk and spacer plate side of the brake piston. The park brake is applied by an internal spring that pushes the brake
piston against the brake disks and spacer plates. Brake disks are splined to the brake housing. Spacer plates are splined to the
park brake drive shaft. When the brake disks and spacer plates are forced together, the park brake drive shaft is prevented
from rotating.
When the park brake switch is disengaged (park brake off), the park brake solenoid valve is energized, which allows charge
pressure oil to flow to the brake disk and spacer plate side of the brake piston. The charge pressure oil overcomes the internal
spring force, forcing the brake piston away from the brake disks and spacer plates. This disengages the park brake and allows
the park brake drive shaft to rotate.

See Hydrostatic Control Valve Operation—Single Speed . (Group 9026-05.)
See Hydrostatic Control Valve Operation—Two Speed . (Group 9026-05.)
Steering Control Operation
Steering System—Hand and Foot Control

LEGEND:
1 Left Steering Lever
2 Right Steering Lever
3 Left Dampener
4 Right Dampener
5 Left Bellcrank
6 Right Bellcrank
7 Left Control Rod
8 Right Control Rod
9 Left Centering Plate
10 Right Centering Plate
11 Left Control Lever
12 Right Control Lever
13 Spring
14 Left Reverse Stop Adjustment Screw
15 Right Reverse Stop Adjustment Screw
16 Left Forward Stop Adjustment Screw
17 Right Forward Stop Adjustment Screw
18 Centering Screw
19 Left Steering Lever Link Rod
20 Right Steering Lever Link Rod
Steering System—Hands Only Control

LEGEND:
1 Left Steering Lever
2 Right Steering Lever
3 Left Dampener
4 Right Dampener
5 Left Bellcrank
6 Right Bellcrank
Section 9026 - HYDROSTATIC SYSTEM Group 15: Diagnostic Information
7 Left Control Rod

8 Right Control Rod
9 Left Centering Plate
10 Right Centering Plate
13 Spring
14 Left Reverse Stop Adjustment Screw
15 Right Reverse Stop Adjustment Screw
16 Left Forward Stop Adjustment Screw
17 Right Forward Stop Adjustment Screw
18 Centering Screw
19 Left Steering Lever Link Rod
20 Right Steering Lever Link Rod
21 Bucket Control Cable (to hydraulic control valve)
22 Boom Control Cable (to hydraulic control valve)
The steering control system provides a means of controlling the direction and speed of the machine by controlling the angle of
the swash plates in the hydrostatic pumps. The angle and orientation of the swash plates control flow and direction of oil in the
hydrostatic system.
The steering control system consists of two steering levers mounted on either side of the operator, centering assemblies
mounted on the hydrostatic pumps and a series of dampeners, bellcranks and control linkages.
The steering levers (1 and 2) connect to the hydrostatic pump control levers (11 and 12) using a series of control linkages (7
and 8) and bellcranks (5 and 6). Operating the levers moves the corresponding control linkages, bellcrank and hydrostatic
pump control lever. The hydrostatic pump control lever then pushes against a spring-loaded centering plate.
Two spring-loaded centering plates (9 and 10), one on each hydrostatic pump, are used. The centering plates force the swash
plates and steering levers to the neutral position whenever the steering levers are released. Each centering plate has a pair of
adjustment screws (14—17) that contact the hydrostatic pump control lever. The adjustment screws provide a means of
adjusting neutral position and to adjust wheel creep.
A dampener (3 and 4) is attached to the bellcrank of each steering lever. The dampeners absorb hydrostatic pulses and torque
feedback into the steering levers. They also provide some resistance to movement of the steering levers.
Moving the left steering lever forward rotates the swash plate inside the left hydrostatic pump in proportion to the movement
of the steering lever. This causes the left hydrostatic pump to displace hydraulic oil at a rate relative to the position of the
swash plate. The hydraulic oil flow from the left hydrostatic pump causes the left hydrostatic motor to operate. This causes the
left wheels to rotate in the forward direction and at a speed relative to the position of the left steering lever. Moving the left
steering lever to the rear causes the left wheels to rotate in the reverse direction and at a speed relative to the position of the
left steering lever.
Operation of the right steering lever is the same as the left except it controls the swash plate in the right hydrostatic pump,
which controls the right wheels.
For machines equipped with hands only control, the left and right steering levers incorporate wrist-actuated handles to operate
the boom and bucket functions.

Hydrostatic System Schematic
329D Single Speed Hydrostatic System Schematic (S.N. —192141)
LEGEND:
1 Left Hydrostatic Motor Housing
7 Left Hydrostatic Motor Closed-Loop Shuttle Spool
8 Orifice
9 Left Hydrostatic Motor Relief Valve
13 Right Hydrostatic Motor Housing
19 Right Hydrostatic Motor Closed-Loop Shuttle Spool
20 Orifice
21 Right Hydrostatic Motor Relief Valve
26 Left Hydrostatic Pump Housing
29 Charge Check Valve
32 Park Brake Spool
34 Right Hydrostatic Pump Housing
44 Hydraulic Pump
46 Charge Pump
53 Return Manifold
121 Left Hydrostatic Pump Control Spool
122 Right Hydrostatic Pump Control Spool
604 Return Oil
707 Charge Oil from Fan System (see Hydraulic System Schematic)
329D Single Speed Hydrostatic System Schematic (S.N. 192142— )
LEGEND:
8 Orifice
20 Orifice
32 Park Brake Spool
44 Hydraulic Pump
46 Charge Pump
53 Return Manifold
82 Orifice (2 used)
88 Bias Piston (2 used)
604 Return Oil
329D and 333D Two Speed Hydrostatic System Schematic (S.N. —192141)
LEGEND:
4 Left Hydrostatic Two Speed Motor (if equipped)
5 Left Hydrostatic Motor Speed Shift Spool (if equipped)
6 Left Hydrostatic Motor Speed Selector Spool (if equipped)
8 Orifice
12 Two Speed Control Spool (if equipped)
16 Right Hydrostatic Two Speed Motor (if equipped)
17 Right Hydrostatic Motor Speed Shift Spool (if equipped)
18 Right Hydrostatic Motor Speed Selector Spool (if equipped)
20 Orifice
32 Park Brake Spool
44 Hydraulic Pump
46 Charge Pump
53 Return Manifold
604 Return Oil
606 Trapped Oil
329D and 333D Two Speed Hydrostatic System Schematic (S.N. 192142— )
LEGEND:
8 Orifice
12 Two Speed Control Spool (if equipped)
20 Orifice
32 Park Brake Spool
44 Hydraulic Pump
46 Charge Pump
53 Return Manifold
82 Orifice (2 used)
88 Bias Piston (2 used)
604 Return Oil
606 Trapped Oil
Hydrostatic System Component Location
Hydrostatic System Component Location—329D Single Speed
LEGEND:
44 Hydraulic Pump
46 Charge Pump
53 Return Manifold
A (S.N. —192141)
B (S.N. 192142— )
Hydrostatic System Component Location—329D and 333D Two Speed
LEGEND:
44 Hydraulic Pump
46 Charge Pump
53 Return Manifold
A (S.N. —192141)
B (S.N. 192142— )
Machine Does Not Move In Either Direction

73
Machine Does Not Move In Either Direction Diagnostic Procedure

Action:
Check hydraulic oil tank level. See Check Hydraulic Reservoir Oil Level . (Operator′s Manual.)
Result:
YES:Go to Park Brake Engaged or Dragging.

NO:Fill tank to correct level with appropriate hydraulic oil.
( 2 ) Park Brake Engaged or Dragging
Action:
Check that park brake releases completely. See Park Brake Release Pressure Test . (Group 9026-25.)
Does park brake release correctly?
Result:
YES:Go to Steering Control Linkage Loose or Broken.

NO:Correct park brake release problem.
( 3 ) Steering Control Linkage Loose or Broken
Action:
Check steering controls and linkages. Are steering controls in good repair and functioning correctly?
Result:

NO:Repair or replace steering control linkage.
Action:
Check for air leak into hydraulic system. Are suction lines or hoses loose or leaking, allowing air into hydraulic system?
Result:

NO:Go to Low Charge Pressure.
( 5 ) Low Charge Pressure
Action:
Check charge pressure in hydraulic system. See Charge Pressure Relief Valve Test . (Group 9025-25.)
Is charge pressure within specification?
Result:
YES:Go to Low Hydrostatic Pump Flow.

NO: See Charge Pump Flow Test . (Group 9025-25.)
( 6 ) Low Hydrostatic Pump Flow
Action:
Is hydrostatic pump flow within specification?
Result:

NO:Repair or replace hydrostatic pumps. See Hydrostatic Pump Remove and Install . (Group 0360.)
Action:
Remove hydrostatic motors and inspect for wear. See Hydrostatic Motor, Park Brake and Gearbox Repair . (Group 0360.)
Result:
YES:Repair or replace hydrostatic motors.

NO:Done.
Hydrostatic Pump Or Hydrostatic Motor Noise

73
Hydrostatic Pump Or Hydrostatic Motor Noise Diagnostic Procedure

Action:
Result:
YES:Go to Low Charge Pressure.

Action:
Result:

NO: See Charge Pump Flow Test . (Group 9025-25.)
Action:
Result:

NO:Go to Park Brake Engaged or Dragging.
Action:
Result:
YES:Go to Hydrostatic Pump Linkage Not Centered in Neutral for One or Both Hydrostatic Pumps.
( 5 ) Hydrostatic Pump Linkage Not Centered in Neutral for One or Both Hydrostatic Pumps
Action:
Check and adjust steering linkage. See Steering Lever Adjustment—Centering . (Group 9026-25.) See Track Speed Test .
(Group 9026-25.) See Tracking Adjustment . (Group 9026-25.)
Does pump noise continue with correct adjustment of steering linkage and centering plate?
Result:
NO:Done.
Action:
Test hydrostatic pump pressure and flow. See Hydrostatic Pump System Pressure Relief Test . (Group 9026-25.) See
Hydrostatic Pump Flow Test . (Group 9026-25.)
Is hydrostatic pump pressure and flow adequate?
Result:
YES:Go to Hydrostatic Motor Worn or Damaged.

NO:Repair or replace. See Hydrostatic Pump Remove and Install . (Group 0360.)
( 7 ) Hydrostatic Motor Worn or Damaged
Action:
Result:
YES:Repair or replace.
NO:Done.
Slow Response To Changes In Speed

73
Slow Response To Changes In Speed Diagnostic Procedure

Action:
Result:
YES:Go to Hydrostatic Pump Linkage Not Centered in Neutral for One or Both Hydrostatic Pumps.
NO:Repair or replace steering control linkage.
( 2 ) Hydrostatic Pump Linkage Not Centered in Neutral for One or Both Hydrostatic Pumps
Action:
Check and adjust steering linkage. See Steering Lever Adjustment—Centering . (Group 9026-25.) See Track Speed Test .
(Group 9026-25.) See Tracking Adjustment . (Group 9026-25.)
Does pump noise continue with correct adjustment of steering linkage and centering plate?
Result:

NO:Done.
Action:
Result:

NO:Go to Low Hydrostatic Pump Flow.
Action:
Result:
YES:Done.
NO:Repair or replace hydrostatic pump. See Hydrostatic Pump Remove and Install . (Group 0360.)
Low Power
73
Low Power Diagnostic Procedure

Action:
Result:

Action:
Result:

NO:Adjust charge pressure relief valve.
Action:
Result:

NO:Go to Low Hydrostatic Pump Flow.
Action:
Result:
YES:Done.
NO:Repair or replace hydrostatic pump. See Hydrostatic Pump Remove and Install . (Group 0360.)
Wheels or Tracks Powered On One Side, Not The Other
73
Wheels or Tracks Powered On One Side, Not The Other Diagnostic

Procedure
Action:
Result:
YES:Go to Steering Control Linkage Loose or Broken.

Action:
Result:
YES:Got to Low Hydrostatic Pump Pressure.

NO:Repair or replace steering control linkage. See Steering Lever Adjustment—Centering . (Group 9026-25.)
( 3 ) Low Hydrostatic Pump Pressure
Action:
Check hydrostatic pump pressure. See Hydrostatic Pump System Pressure Relief Test . (Group 9026-25.)
Are hydrostatic pump pressure relief valves within specification?
Result:

NO:Repair or replace hydrostatic pump pressure relief valves.
Action:
Result:

NO:Done.
Machine Will Not Shift Into Or Out Of High Speed
73
Machine Will Not Shift Into Or Out Of High Speed Diagnostic Procedure
( 1 ) Two Speed Proportional Solenoid Valve Does Not Operate
Action:
Check two speed proportional solenoid. See Solenoid Test . (Group 9015-20.) Does the two speed proportional solenoid pass
the solenoid test?
Result:

NO:Replace two speed proportional solenoid.
Action:
See Charge Pump Flow Test . (Group 9025-25.)
Result:
YES:Go to Valves In Hydrostatic Motor Not Shifting.

NO:Replace charge pump. See Charge Pump Remove and Install . (Group 3160.)
( 3 ) Valves In Hydrostatic Motor Not Shifting
Action:
Repair hydrostatic motor. See Hydrostatic Motor, Park Brake and Gearbox Repair . (Group 0360.)
Result:
OK:Done.
Machine Creeps With Steering Levers In Neutral

84
Machine Creeps With Steering Levers In Neutral Diagnostic Procedure

( 1 ) Bent Control Rods
Action:
Check control rods. Are either of the control rods bent?
Result:
YES:Repair or replace control rods. See Steering Cross Shaft Assembly Remove and Install . (Group 0315.)
NO:Go to Centering Springs Improperly Adjusted.
( 2 ) Centering Springs Improperly Adjusted
Action:
Check centering spring adjustment. See Steering Lever Adjustment—Centering . (Group 9026-25.) See Tracking Adjustment .
(Group 9026-25.)
Does machine creep continue with correct adjustment of centering springs?
Result:
YES:Go to Worn Pivot Bearings On Drive Control Levers.

NO:Done.
( 3 ) Worn Pivot Bearings On Drive Control Levers
Action:
Inspect pivot bearings. Are pivot bearings on drive control levers worn? See Control Lever Remove and Install . (Group 0315.)
Result:
YES:Go to Worn Centering Hardware.

NO:Replace pivot bearings.
( 4 ) Worn Centering Hardware
Action:
Check for worn centering hardware. See Steering Cross Shaft Assembly Remove and Install . (Group 0315.) See Steering Cross
Shaft Disassemble and Assemble . (Group 0315.)
Does pump noise continue with replaced hardware?
Result:
YES:Go to Broken Centering Spring.

NO:Done.
( 5 ) Broken Centering Spring
Action:
Check for broken centering spring. See Steering Cross Shaft Assembly Remove and Install . (Group 0315.) See Steering Cross
Result:
YES:Go to Broken Steering Dampener.
NO:Done.
( 6 ) Broken Steering Dampener
Action:
Check steering dampeners. See Steering Dampener Inspection . (Group 0315.)

Are steering dampeners working correctly?
Result:
YES:Done.
NO:Replace steering dampener. See Steering Dampener Remove and Install . (Group 0315.)
Hydrostatic System Noise While In Neutral

84
Hydrostatic System Noise While In Neutral Diagnostic Procedure

Action:
(Group 9026-25.)
Result:

NO:Done.
Action:
Result:

NO:Done.
Action:
Result:
YES:Go to Broken Steering Dampener.

NO:Done.
( 4 ) Broken Steering Dampener
Action:

Result:
YES:Done.
Steering Levers Hard To Move

84
Steering Levers Hard To Move Diagnostic Procedure

Action:
Result:
NO:Go to Worn Pivot Bearings On Drive Control Levers.
Action:
Result:

Action:
Result:

NO:Done.
Action:
Result:
YES:Go to Damaged Link Rod End.

NO:Done.
( 5 ) Damaged Link Rod End
Action:
Check steering link rod ends. Is either link rod end damaged?
Result:
YES:Repair or replace link rod ends. See Control Lever Remove and Install . (Group 0315.)
NO:Done.
Steering Levers Feel Loose Or “Sloppy”

84
Steering Levers Feel Loose Or “Sloppy” Diagnostic Procedure

( 1 ) Cab Not Secured
Action:
Check that cab is properly secured to machine. Is cab properly secured? See Raising Operator′s Station . (Operator′s Manual.)
Result:

NO:Secure cab.
Action:
Result:
NO:Go to Worn Control Rod Bushing.
( 3 ) Worn Control Rod Bushing
Action:
Check control rod bushing. Is bushing worn, causing looseness in steering control levers?
Result:
YES:Replace control rod bushing. See Steering Cross Shaft Assembly Remove and Install . (Group 0315.)
NO:Go to Centering Springs Improperly Adjusted.
Action:
(Group 9026-25.)
Result:
YES:Go to Worn Pivot Bearings On Drive Control Levers.

NO:Done.
Action:
Result:

Action:
Result:

NO:Done.
Action:
Is there a broken spring?
Result:
YES:Replace spring.
NO:Done.
Machine Tracks To One Side With Steering Levers In Full Forward Or Reverse Position
84
Machine Tracks To One Side With Steering Levers In Full Forward Or

Reverse Position Diagnostic Procedure
( 1 ) Steering Lever Improperly Adjusted
Action:
(Group 9026-25.)
Are the steering levers properly adjusted?
Result:
YES:Go to Tracking Out of Adjustment.

NO:Adjust linkage.
( 2 ) Tracking Out of Adjustment
Action:
Check and adjust machine tracking. Does tracking adjustment correct problem? See Track Speed Test . (Group 9026-25.) See
Tracking Adjustment . (Group 9026-25.)
Result:
YES:Done.
NO:Go to Bent Control Rods.
Action:
Result:
Action:
Result:
NO:Go to Worn Pivot Bearings On Drive Control Levers.
Action:
Inspect pivot bearings. See Control Lever Remove and Install . (Group 0315.)
Result:
YES:Done.
Steering Levers Pulse Or Vibrate Excessively
84
Steering Levers Pulse Or Vibrate Excessively Diagnostic Procedure

→NOTE:
The hydrostatic pumps produce some steering lever vibration during normal operation.
( 1 ) Cab Not Secured
Action:
Check that cab is properly secured to machine. Is cab properly secured? See Raising Operator′s Station . (Operator′s Manual.)
Result:

NO:Secure cab.
Action:
Result:
Action:
Result:
NO:Done.
( 4 ) Worn Steering Dampener
Action:

Result:
YES:Done.
Park Brake Does Not Hold (Single Speed)

62
Park Brake Does Not Hold Diagnostic Procedure (Single Speed)

( 1 ) Park Brake Switch and Circuit Check
Action:
→NOTE:
Make sure when park brake switch is ON, park brake is ON.
Check park brake switch and related wiring using engagement and monitor unit (EMU) diagnostic menu. See Engagement and
Monitor Unit Data Items . (Group 9015-16.)
Does park brake switch and wiring pass inspection?
Result:
YES:Go to Park Brake Solenoid Check.

NO:Repair or replace switch and wiring, as needed.
( 2 ) Park Brake Solenoid Check
Action:
→NOTE:
Valve should be de-energized when park brake is ON.
Check park brake solenoid. See Solenoid Test . (Group 9015-20.)

Is park brake solenoid functioning correctly?
Result:
YES:Go to Hydrostatic Control Valve Leakage.

NO:Repair or replace park brake solenoid.
( 3 ) Hydrostatic Control Valve Leakage
Action:
Check for charge pressure at hydrostatic control valve by teeing into line and measuring pressure. Pressure should be zero (0)
with machine running and park brake ON. See Park Brake Release Pressure Test . (Group 9026-25.)
Is charge pressure zero (0) with machine running and park brake ON?
Result:
YES:Go to Park Brake Lining or Disk Check.

NO:Replace hydrostatic control valve. See Hydrostatic Control Valve Remove and Install . (Group 0360.)
( 4 ) Park Brake Lining or Disk Check
Action:
Inspect park brake lining or disk. See Hydrostatic Motor, Park Brake and Gearbox Repair . (Group 0360.)
Does park brake lining or disk pass inspection?
Result:
YES:Done.
NO:Repair or replace park brake assembly.
Park Brakes Do Not Release (Single Speed)

62
Park Brakes Do Not Release Diagnostic Procedure (Single Speed)

( 1 ) Seat Switch Check
Action:
Sit in seat. Does seat switch indicator go OFF?
Result:
YES:Go to Interlocking Seat Bar Switch Check.

NO:Check operation of seat switch using engagement and monitor unit (EMU) diagnostic menu. See Engagement and Monitor
Unit Data Items . (Group 9015-16.)
( 2 ) Interlocking Seat Bar Switch Check
Action:
Lower interlocking seat bar. Does interlocking seat bar switch indicator go OFF?
Result:
YES:Go to Cab Door Switch Check.

NO:Check operation of interlocking seat bar switch using engagement and monitor unit (EMU) diagnostic menu. See
Engagement and Monitor Unit Data Items . (Group 9015-16.)
( 3 ) Cab Door Switch Check
Action:
Close cab door, if equipped. Does cab door switch indicator go OFF?
→NOTE:
If machine is not equipped with cab door, the EMU still needs a closed cab door switch circuit to release
park brake. Make sure that cab door switch jumper is properly connected.
Result:

NO:Check operation of cab door switch using engagement and monitor unit (EMU) diagnostic menu. See Engagement and
Action:

Result:
YES:Go to Park Brake Switch and Circuit Check.

Action:
Check park brake switch and related wiring. See System Functional Schematic . (Group 9015-10.)
Are park brake switch and wiring ok?
Result:
YES:Go to Park Brake Release Pressure Check.

( 6 ) Park Brake Release Pressure Check
Action:
Check park brake release pressure. See Park Brake Release Pressure Test . (Group 9026-25.)
Is park brake release pressure within specification?
Result:

NO:Correct park brake release pressure problem.
Action:
Result:
YES:Done.
Grinding Noise While Operating Machine (Single Speed)
62
Grinding Noise While Operating Machine Diagnostic Procedure (Single

Speed)
Action:
→NOTE:
A minimum of 1400 kpa (14 bar) (200 psi) must be available to fully release park brake.
Is park brake release pressure within specification?
Result:

NO:Correct park brake release pressure problem.
Action:

Result:

Action:
Doe park brake lining or disk pass inspection?
Result:
YES:Done.
Park Brake Does Not Hold (Two Speed)

62
Park Brake Does Not Hold Diagnostic Procedure (Two Speed)

Action:
→NOTE:
Make sure when park brake switch is ON, park brake is ON.
Check park brake switch and related wiring using engagement and monitor unit (EMU) diagnostic menu. See Engagement and
Does park brake switch and wiring pass inspection?
Result:

Action:
→NOTE:
Valve should be de-energized when park brake is ON.

Result:
YES:Go to Hydrostatic Control Valve Leakage.

( 3 ) Hydrostatic Control Valve Leakage
Action:
Check for charge pressure at hydrostatic control valve by teeing into line and measuring pressure. Pressure should be zero (0)
with machine running and park brake ON. See Park Brake Release Pressure Test . (Group 9026-25.)
Is charge pressure zero (0) with machine running and park brake ON?
Result:

NO:Replace hydrostatic control valve. See Hydrostatic Control Valve Remove and Install . (Group 0360.)
Action:
Result:
YES:Done.
Park Brakes Do Not Release (Two Speed)

62
Park Brakes Do Not Release Diagnostic Procedure (Two Speed)

( 1 ) Seat Switch Check
Action:
Sit in seat. Does seat switch indicator go OFF?
Result:
YES:Go to Interlocking Seat Bar Switch Check.

NO:Check operation of seat switch using engagement and monitor unit (EMU) diagnostic menu. See Engagement and Monitor
Unit Data Items . (Group 9015-20.)
( 2 ) Interlocking Seat Bar Switch Check
Action:
Lower interlocking seat bar. Does interlocking seat bar switch indicator go OFF?
Result:
YES:Go to Cab Door Switch Check.

NO:Check operation of interlocking seat bar switch using engagement and monitor unit (EMU) diagnostic menu. See
Engagement and Monitor Unit Data Items . (Group 9015-20.)
( 3 ) Cab Door Switch Check
Action:
Close cab door, if equipped. Does cab door switch indicator go OFF?
→NOTE:
If machine is not equipped with cab door, the EMU still needs a closed cab door switch circuit to release
park brake. Make sure that cab door switch jumper is properly connected.
Result:

NO:Check operation of cab door switch using engagement and monitor unit (EMU) diagnostic menu. See Engagement and
Action:

Result:
YES:Go to Charge Pressure Check.

( 5 ) Charge Pressure Check
Action:
→NOTE:
Check machine charge pressure. Charge pressure is used to apply park brake. See Charge Pressure Relief Valve Test . (Group
9025-25.)
Result:

NO:Replace charge pump. See Charge Pump Flow Test . (Group 9025-25.) See Charge Pump Remove and Install . (Group
3160.)
Action:
IMPORTANT:
Avoid damage to park brake seals. Do not pressurize park brake beyond test specification.
Check park brake ability to hold pressure. Install hand pump to manually pressurize park brake to 2070 kPa (20.7 bar) (300
psi). The park brake should hold test pressure for at least 5 minutes. If brakes do not hold pressure, pump up brakes
individually to determine which brake has internal leakage.
Result:

NO:Repair or replace park brake assembly. See Hydrostatic Motor, Park Brake and Gearbox Repair . (Group 0360.)
Action:
Doe park brake lining or disk pass inspection?
Result:
YES:Done.
Section 9026 - HYDROSTATIC SYSTEM Group 25: Tests
Grinding Noise While Operating Machine (Two Speed)

62
Grinding Noise While Operating Machine Diagnostic Procedure (Two

Speed)
( 1 ) Charge Pressure Check
Action:
→NOTE:
Check machine charge pressure. Charge pressure is used to apply park brake. See Charge Pressure Relief Valve Test . (Group
9025-25.)
Result:

NO:Replace charge pump. See Charge Pump Flow Test . (Group 9025-25.) See Charge Pump Remove and Install . (Group
3160.)
Action:
IMPORTANT:
Avoid damage to park brake seals. Do not pressurize park brake beyond test specification.
Check park brake ability to hold pressure. Install hand pump to manually pressurize park brake to 2070 kPa (20.7 bar) (300
psi). The park brake should hold test pressure for at least 5 minutes. If brakes do not hold pressure, pump up brakes
individually to determine which brake has internal leakage.
Result:

NO:Repair or replace park brake assembly. See Hydrostatic Motor, Park Brake and Gearbox Repair . (Group 0360.)
Action:
Result:
YES:Done.
Group 25 - Tests
Engine Speed Control for Testing
Engine Speed Dial
→NOTE:
If using JT0KV12444A Remote Start Box with internal engine speed control dial, a separate engine speed
control dial is not necessary. See Remote Start Box Installation . (Group 9025-25.)
AT340550 Potentiometer
AL76568 Turning Knob
[1] -
LEGEND:
1 Right Frame
2 Remote Start Box
3 Engine Speed Dial
Engine Speed Dial

Install engine speed dial (3) in service engine speed control 3-pin connector (X9), located on right frame (1) of machine.
Potentiometer
AT340550
Used for engine speed control.
Turning Knob
AL76568
Used for engine speed control.
[2] - Use engine speed dial to control engine speed when testing machine with operator′s station in the raised position.
Service Advisor™
[1] - Make sure service computer is connected to machine. See Service ADVISOR™ Connection Procedure . (Group 9015-20.)
[2] - Make sure machine is properly raised and supported. See Raising and Blocking Machine . (Operator′s Manual.)
[4] - Access Service ADVISOR ™ engine speed control menu and press OK.
[5] - Press OK to confirm that machine is safely raised and supported. See Raising and Blocking Machine . (Operator′s Manual.)
[6] -
→NOTE:
The engine control unit (ECU) will not let you go above or below the programmed engine rpm for the
machine.
Engine Speed Control

Manually enter the desired engine rpm and press OK.
Hydrostatic Pump System Pressure Relief Test
Hydrostatic Pump Ports (left side)
Hydrostatic Pump Ports (right side)

LEGEND:
131 Left Forward Hydrostatic Motor Port (1-5/16-12 UN-2B)
132 Left Reverse Hydrostatic Motor Port (1-5/16-12 UN-2B)
133 Right Forward Hydrostatic Motor Port (1-5/16-12 UN-2B)
134 Right Reverse Hydrostatic Motor Port (1-5/16-12 UN-2B)
Specifications
SPECIFICATIONS
43°C
110°F
SPECIFICATIONS
37 400—39 500 kPa

Hydrostatic Pump High Pressure Relief Valve Pressure (S.N. —192141) 374—395 bar
5430—5730 psi
34 000—36 000 kPa

Hydrostatic Pump High Pressure Relief Valve Pressure (S.N. 192142— ) 340—360 bar
4930—5230 psi
JT02156 Digital Pressure/Temperature Analyzer
Quick Coupler
JT02160 10 000 PSI Transducer
This test ensures that the hydrostatic pump pressure relief valves are operating properly.
[1] -
IMPORTANT:
Ensure that the hydraulic fluid in the hydraulic oil tank is at the full mark. Insufficient hydraulic fluid
could cause the system to run dry and damage pumps and motors.
Operate machine until hydraulic oil reaches specification.

110°F
[2] - Remove front attachment and park machine on flat and level surface.
[4] -
CAUTION:
pressure.
Stop engine and relieve hydraulic system pressure. See Hydraulic System Pressure Release . (Group 9025-25.)
[5] - If engine speed will be controlled by using Service ADVISOR ™ connect service computer to machine at this time. See
[7] -
→NOTE:
control dial is not necessary.
If engine speed will be controlled by using a separate engine speed dial, see Engine Speed Control for Testing . (Group
9026-25.)
[8] - Install M8 x 30 cap screws in tab at the rear of both yokes of control levers to secure levers during test procedure.
[9] -
CAUTION:
[10] - Check and record charge pressure. See Charge Pressure Relief Valve Test . (Group 9025-25.)
[11] - Remove hydraulic line from left forward hydrostatic motor port (131) to left hydrostatic motor.
[12] - Cap line to left hydrostatic motor.
[13] - Install quick coupler into left forward hydrostatic motor port (131).
[14] - Attach JT02160 10 000 PSI Transducer and JT02156 Digital Pressure Temperature Analyzer. See JT02156A Digital
Pressure/Temperature Analyzer Installation . (Group 9025-25.)
JT02156
To measure hydrostatic pump pressure relief.
Quick Coupler

10 000 PSI Transducer
JT02160
[15] - Start engine and run at fast idle.

[16] - Slowly move corresponding control lever (left) in appropriate direction (forward) to test left forward relief valve.
[17] -
→NOTE:
Charge pressure must be subtracted from pressure reading to obtain hydrostatic pump pressure relief
valve pressure.
Record pressure reading. Subtract charge pressure from pressure reading to obtain hydrostatic pump pressure relief valve
pressure.
Hydrostatic Pump High Pressure Relief Valve Pressure (S.N. —192141) 37 400—39 500 kPa
374—395 bar
5430—5730 psi
Hydrostatic Pump High Pressure Relief Valve Pressure (S.N. 192142—) 34 000—36 000 kPa
340—360 bar
4930—5230 psi
[18] - Repeat procedure for remaining relief valves as necessary.
[19] - If pressure is not within specifications, replace the corresponding relief valve. See Hydrostatic Pump
[20] - Install hydraulic line from left forward hydrostatic motor port to left hydrostatic motor.
Track Speed Test

Specifications
SPECIFICATIONS
43°C
Hydraulic Oil Operating Temperature
110°F
Single Speed (S.N. —192141)
Gearbox Housing Rotations Speed 111—116 rpm
Two Speed (S.N. —192141)
Single Speed (S.N. 192142— )
Two Speed Low (S.N. 192142— )
Two Speed High (S.N. 192142— )
This test is an initial test to verify hydrostatic system is operating normally.
[1] -
IMPORTANT:
Ensure hydraulic oil tank is at the full mark. Insufficient hydraulic oil could damage pumps and motors.
Operate machine until hydraulic oil reaches normal operating temperature.

Hydraulic Oil Operating Temperature 43°C
110°F
[5] - If engine speed will be controlled by using Service ADVISOR™ connect service computer to machine at this time. See
[7] -
→NOTE:
9026-25.)
[8] - Install M8 x 30 cap screws in tab at the rear of both yokes of control levers to secure levers in an upright position.
[9] -
CAUTION:
Avoid possible injury from moving tires when using remote start box. Keep tire area clear of bystanders.
Do not use remote start box without raising and blocking skid steer loader. Skid steer loader may
override brake and move quickly.
[10] -
LEGEND:
1 Reflective Tape
2 Hydrostatic Motor Gearbox Housing
Hydrostatic Motor Gearbox Housing

Apply reflective tape (1) to hydrostatic motor gearbox housing (2) on each side of the machine.
JT05719
Used to measure track rpm.

[12] -
→NOTE:
If equipped with two speed option, track speed is tested with two speed set to high range.
Move control lever to full rearward position. Measure and record gearbox housing rotations in 1 minute.
Single Speed (S.N. —192141)

Two Speed (S.N. —192141)

Single Speed (S.N. 192142— )

Two Speed Low (S.N. 192142— )

Two Speed High (S.N. 192142— )

[13] - Repeat procedure for the opposite side.
[14] - Stop engine.
[15] - If gearbox housing speeds are outside of the listed ranges after tracking adjustment, check the following:
Perform tracking adjustment. See Tracking Adjustment . (Group 9026-25.)

Inspect brakes for dragging.
Perform hydrostatic pump flow test. See Hydrostatic Pump Flow Test . (Group 9026-25.)
Repair hydrostatic motor. See Hydrostatic Motor, Park Brake and Gearbox Repair . (Group 0360.)
Hydrostatic Pump Flow Test
Hydrostatic Pump Ports (left side)
Hydrostatic Pump Ports (right side)

LEGEND:
131 Left Forward Hydrostatic Motor Port
132 Left Reverse Hydrostatic Motor Port
133 Right Forward Hydrostatic Motor Port
134 Right Reverse Hydrostatic Motor Port
Specifications
SPECIFICATIONS
43°C
110°F
SPECIFICATIONS
13 790 kPa
Hydrostatic Pump Testing Pressure 137.9 bar
2000 psi
105.6 L/min
Hydrostatic Pump Flow Rate (typical, new)
27.9 gpm
84.4 L/min
Hydrostatic Pump Flow Rate (minimum)
22.3 gpm
JT07148 Digital Hydraulic Flowmeter Tester
This test is to ensure the hydrostatic pumps are delivering sufficient oil flow to the hydrostatic motors.
[1] -
IMPORTANT:
110°F
[4] -
CAUTION:
pressure.
[7] -
→NOTE:
9026-25.)
[8] -
CAUTION:
[10] - For left hydrostatic pump (27), use left forward hydrostatic motor port (131) and left reverse hydrostatic motor port
(132).
[11] - Attach JT07148 Digital Hydraulic Flowmeter Tester

JT07148
Used to measure hydrostatic pump flow.
from left forward hydrostatic motor port to left reverse hydrostatic motor port. Turn load valve all the way open on JT07148
Digital Hydraulic Flowmeter Tester.
[12] - Cap or plug all openings to left hydrostatic motor.
[13] - Run at fast idle and push left control lever all the way forward.
[14] - Slowly turn load valve in on JT07148 Digital Hydraulic Flowmeter Tester. Increase pressure to specification.
Hydrostatic Pump Testing Pressure 13 790 kPa
137.9 bar
2000 psi
[15] - Read and record pump flow.

Hydrostatic Pump Flow Rate (typical, new) 105.6 L/min
27.9 gpm
Hydrostatic Pump Flow Rate (minimum) 84.4 L/min
22.3 gpm
[16] - Repeat procedure for right hydrostatic pump (35) using right forward hydrostatic motor port (133) and right reverse
hydrostatic motor port (134).
[17] - If flow is low:
Verify engine speed at fast idle.

Disconnect linkage from levers on pump. Operate levers manually. If flow is now ok, check linkage and adjust as
necessary.
Verify proper control lever travel. See Steering Lever Adjustment—Centering . (Group 9026-25.)
Verify charge oil supply is sufficient.
Disassemble and inspect hydrostatic pump. See Hydrostatic Pump Disassemble—329D, 332D, 333D . (Group 0360.)
Hydrostatic Pump Neutral Adjustment
Hydrostatic Pump Neutral Adjustment (left side)
Hydrostatic Pump Neutral Adjustment (right side)

LEGEND:
146 Neutral Adjustment Screw (2 each)
158 Left Hydrostatic Pump Control Spool Neutral Adjustment Screw
159 Right Hydrostatic Pump Control Spool Neutral Adjustment Screw
Specifications
SPECIFICATIONS
207 kpa
Pressure from Forward Port to Reverse Port Difference 2 bar
30 psi
SPECIFICATIONS
18 N·m
Hydrostatic Pump Neutral Adjustment Screw Lock Nut Torque
160 lb-in.
20 N·m
Control Spool Neutral Adjustment Screw Lock Nut Torque
175 lb-in.
Quick Couplers
JT02161 500 PSI Transducer
This adjustment provides an absolute neutral condition within the hydrostatic pump.
[1] -
→NOTE:
If installing hydrostatic pump components, perform this procedure instead of adjusting track creep to
establish an absolute neutral condition within the hydrostatic pump.
Remove front attachment and park machine on flat level surface.
[3] -
CAUTION:
pressure.
[6] -
→NOTE:
9026-25.)
[8] -
CAUTION:
Prevent possible injury from moving tires when using remote start box. Keep tire area clear of
bystanders. Do not use remote start box without raising and blocking machine.
[9] - Remove lines from ports (131) and (132) to left hydrostatic motor from left hydrostatic pump (27).
[10] - Install quick couplers in each hydrostatic pump port.

Quick Couplers
To measure system pressure at both forward and reverse ports in order to adjust true neutral on the servo.
[11] - Cap lines to left hydrostatic motor.
[12] - Attach JT02161 500 PSI Transducers to each coupler and use JT02156A Digital Pressure/Temperature Analyzer. See
JT02156A Digital Pressure/Temperature Analyzer Installation . (Group 9025-25.)
500 PSI Transducer
JT02161
JT02156A
[13] -
LEGEND:
5 Left Steering Lever Linkage
6 Left Hydrostatic Pump Control Arm
7 Neutral Adjustment Screw Lock Nut
8 End Plate
Hydrostatic Linkage
Disconnect left steering lever linkage (5) from left hydrostatic pump control arm (6).
[14] - Loosen neutral adjustment screw lock nut (7) on the neutral adjustment screw (146) in center of end plate (8).

[17] - Record pressure readings from both ports.

Pressure from Forward Port to Reverse Port Difference 207 kpa
2 bar
30 psi
[18] - Turn the neutral adjustment screw (8) until pressure readings are within 30 psi of each other.
[19] - Shut off engine.
[20] - Tighten neutral adjustment screw lock nut to specification.

Hydrostatic Pump Neutral Adjustment Screw Lock Nut Torque 18 N·m
160 lb-in.
[21] - Remove quick couplers and install lines from hydrostatic motors to hydrostatic pump.
[22] -
Hydrostatic Pump Neutral Adjustment (left side)
Hydrostatic Pump Neutral Adjustment (right side)

LEGEND:
146 Neutral Adjustment Screw (2 each)
158 Left Hydrostatic Pump Control Spool Neutral Adjustment Screw
159 Right Hydrostatic Pump Control Spool Neutral Adjustment Screw
Loosen lock nut on left hydrostatic pump control spool neutral adjustment screw (158).

[24] - Turn left hydrostatic pump control spool neutral adjustment screw until wheels just begin to turn. Mark position of screw.
[25] - Turn left hydrostatic pump control spool neutral adjustment screw in the opposite direction until wheels just begin to
turn. Mark position of screw.
[26] - Turn left hydrostatic pump control spool neutral adjustment screw to midpoint. Hold screw and tighten lock nut to
specification.
Control Spool Neutral Adjustment Screw Lock Nut Torque 20 N˙m
175 lb-in.
[27] - Stop engine.
[28] -
LEGEND:
8 End Plate
Hydrostatic Linkage
Loosen lock nuts on left steering lever linkage (5) and adjust so link goes into left hydrostatic pump control arm (6) without
moving it.
[29] - Connect left steering lever linkage to left hydrostatic pump control arm.
[30] - Repeat procedure for right hydrostatic pump.
Track Creep Adjustment

LEGEND:
8 End Plate
Hydrostatic Linkage
Specifications
SPECIFICATIONS
18 N·m
Set Screw Lock Nut Torque
160 lb-in.
Track creep adjustment is done to remove track creep from machine.
→NOTE:
If installing hydrostatic pump components, perform the pump neutral adjustment instead of this
procedure to establish an absolute neutral condition within the hydrostatic pump. See Hydrostatic Pump
Neutral Adjustment . (Group 9026-25.)
[1] -
IMPORTANT:
Ensure hydraulic oil tank is at the full mark. Insufficient hydraulic oil could damage pumps and motors
110°F
[4] -
CAUTION:
pressure.
[7] -
→NOTE:
9026-25.)
[8] -
CAUTION:
[11] - Run engine at fast idle and check for track creep.
[12] - If there is track creep, shut off engine and disconnect steering links at the hydrostatic pump control levers.
[14] - Note the side and direction of track creep.
[15] - Loosen neutral adjustment screw lock nut (7) on neutral adjustment screw (146) in the end plate (8) of the pump for the
side that is creeping. If it is the left side, make adjustment on the forward pump, if it is the right, make adjustment on the rear
pump.

[17] - Function the hydrostatic pump control levers back and forth a few times and allow it to return to neutral.
[18] -
→NOTE:
If the right track is creeping forward, turn the screw in (clockwise) on the rear pump. If the right track is
creeping in reverse, turn the screw out (counterclockwise) on the rear pump. If the left track is creeping
forward, turn the screw of the front pump out (counterclockwise). If the left track is creeping in reverse,
turn the screw of the front pump in (clockwise).
Turn neutral adjustment screw until track stops moving. Mark the position of the neutral adjustment screw.
[19] - Turn neutral adjustment screw in the opposite direction until the track begins to turn in the opposite direction. Mark the
position.
[20] - Turn set screw to midpoint between marks. Tighten lock nut to specification.
Set Screw Lock Nut Torque 18 N·m
160 lb-in.
[21] - Stop engine.
[22] - Repeat procedure with other servo.
[23] - Check that centering assembly is correctly adjusted. See Centering Assembly Adjustment . (Group 9026-25.)
Steering Lever Effort Adjustment

Specifications
SPECIFICATIONS
40 N·m
Control Lever Link Rod Hardware Torque
30 lb-ft
This adjustment modifies the feel and effort of control lever.
[4] -
LEGEND:
1 Pump Control Linkage (2 each)
2 Cross Shaft Bellcrank (2 each)
3 Upper Bellcrank Hole
4 Lower Bellcrank Hole
Steering Effort Adjustment

Disconnect both pump control linkages (1) from the cross shaft bellcranks (2).
[5] - Connect the pump control linkages to the cross shaft bellcrank as follows:
Upper hole provides the greatest steering effort and the shortest control lever stroke.
Middle hole is the factory setting.
Lower hole provides the least steering effort and the longest control lever stroke.
[6] - Install lock nuts and tighten to specification.

Control Lever Link Rod Hardware Torque 40 N·m
30 lb-ft
[7] - Adjust centering assembly. See Centering Assembly Adjustment . (Group 9026-25.)
[8] - Adjust center position of both control levers. See Steering Lever Adjustment—Centering . (Group 9026-25.)
[9] - Adjust stop screws on both control levers. See Tracking Adjustment . (Group 9026-25.)
Centering Assembly Adjustment

Specifications
SPECIFICATIONS
75 mm
Forward Spring Length
2.95 in.
85 mm
Reverse Spring Length
3.35 in.
40 N·m
Control Lever Link Rod Hardware Torque
30 lb-ft
This adjustment is to prevent the machine from creeping when control levers are in neutral.
[5] -
→NOTE:
9026-25.)
[7] - Check pivot points of all the steering linkage for wear and damage. Repair linkage components prior to performing these
adjustments.
[8] -
CAUTION:
[9] -
→NOTE:
To ease later assembly, note hole position of linkages before removing from cross shaft (3) bellcranks.
LEGEND:
1 Steering Lever Link Rod (2 used)
2 Steering Dampener (2 used)
3 Cross Shaft (2 used)
Steering Lever Link Rod

Disconnect both steering lever link rods (1) from cross shaft bellcranks.
[10] - Disconnect both steering dampeners (2) from cross shaft bellcranks.
[11] -
Hydrostatic Pump Control Linkage

LEGEND:
4 Forward Spring
5 Forward Spring Bolt Lock Nut
6 Centering Link (2 each)
7 Reverse Spring (2 each)
8 Pump Control Linkage (2 each)
9 Ball Joint (2 each)
10 Rear Plate
11 Reverse Spring Lock Nuts (4 each)
12 Right Centering Link Bolt Head
13 Left Centering Link Bolt Head
14 Bushing
15 Support Bracket Guide Plate
Loosen forward spring bolt lock nut (5) and adjust forward spring (4) length to specification.
Forward Spring Length 75 mm
2.95 in.
[12] - Loosen both centering link (6) ball joint (9) lock nuts.
[13] - Loosen both reverse spring (7) lock nuts (11). Rotate centering links (6) until there is clearance between rear plate (10)
and bolt head of centering links (12 and 13).
[14] - Adjust left centering link until right centering link bolt head just touches the rear plate (10). Repeat with right centering
link. Rear plate should be perpendicular to the linkage. Tighten both ball joint (9) lock nuts.
[15] - Adjust reverse spring nuts until each spring is to specification.

Reverse Spring Length 85 mm
3.35 in.
[16] - Connect control lever link rods to cross shaft bellcranks. Install lock nuts and tighten to specification.
Control Lever Link Rod Hardware Torque 40 N·m
30 lb-ft
[19] - Adjust stop screws on both control levers. See Tracking Adjustment . (Group 9026-25.)
Steering Lever Adjustment—Centering

→NOTE:
Centering assembly must be properly adjusted to perform control lever centering adjustment.
This adjustment centers the control levers.
[4] -
LEGEND:
1 Left Link Rod
2 Lock Nut (2 used)
4 Left Lever Casting
5 Left Link Rod Pivot Bearing
Steering Lever Adjustment—Centering

Loosen both lock nuts (2) on left link rod (1) on left control lever (3).
[5] - Adjust left link rod to align left lever casting (4) with left link rod pivot bearing (5).
[6] - Tighten both lock nuts on left link rod.
[7] - Repeat procedure for right control lever.
[8] -
IMPORTANT:
The control lever stops must be adjusted properly to prevent damage to the linkage and internal
hydrostatic components.
Adjust control lever stops. See Tracking Adjustment . (Group 9026-25.)
Tracking Adjustment
LEGEND:
1 Left Forward Stop Screw
2 Left Forward Stop Screw Lock Nut
3 Left Forward Stop
4 Left Reverse Stop Screw
5 Left Reverse Stop Screw Lock Nut
6 Left Reverse Stop
Lever Stop Screw
Specifications
SPECIFICATIONS
7.7—10.8 N·m
Pump Adjustment Screw Lock Nut Torque
68—96 lb-in.
Single Speed
Track Speed 111—116 rpm
Two Speed High
IMPORTANT:
If steering system adjustments have been made for any reason, the control lever stops must be adjusted.
The control lever stops must be adjusted first to prevent damage to the linkage and internal hydrostatic
components.
This procedure contains two adjustments that must both be made for correct tracking of machine and for the prevention of
internal hydrostatic pump damage.
[3] -
CAUTION:
pressure.
[6] -
→NOTE:
9026-25.)
[7] - Install M8 x 30 cap screws in tab at the rear of both yokes of control levers to secure levers during adjustment procedure.
[8] -
CAUTION:
[9] - Loosen left forward stop screw lock nut (2) on the left forward stop screw (1).
[10] - Turn left forward stop screw in (clockwise).
[11] -
→NOTE:
The control lever stop screws act as the primary stop just before the mechanism inside the hydrostatic
pump stops movement of the pump control lever.
Move and hold left control lever at the full forward position.
[12] - Turn left forward stop screw out (counterclockwise) until it just contacts the left forward stop (3). Then turn left forward
stop screw out an additional three full turns.
[13] - Hold left forward stop screw and tighten left forward stop screw lock nut.
[14] - Loosen left reverse stop screw lock nut (5) on left reverse stop screw (4).
[15] - Move and hold left control lever at the full reverse position.
[16] - Turn left reverse stop screw until it just contacts left reverse stop (6). Then turn left reverse stop screw out an additional
three full turns. Tighten left reverse stop screw lock nut.
[17] - Repeat procedure to set control lever stops for right side.
[18] - Apply reflective tape to one track on each side of the machine.

[20] -
→NOTE:
If equipped with two speed option, tracking is set with two speed set to high range.
Holding the left control lever in the full forward position. Measure and record the full forward track speed (revolutions per
minute) of the left wheels using JT05719 Photo Tachometer.
JT05719
Used to measure track speed.
[21] - Repeat step to measure and record full forward track speed for right track.
[22] - Compare track speeds to specification. Left and right track speeds should be the same and within specification. Adjust
track speeds as necessary; always adjust the faster track to equal the slower track.
Single Speed
Two Speed High

[23] -
→NOTE:
Do not adjust neutral adjustment screws (15—16). These screws are used for neutral adjustment only.
LEGEND:
7 Right Forward Pump Adjustment Screw
8 Lock Nut
9 Left Forward Pump Adjustment Screw
10 Lock Nut
11 Right Reverse Pump Adjustment Screw
12 Lock Nut
13 Left Reverse Pump Adjustment Screw
14 Lock Nut
15 Right Hydrostatic Pump Neutral Adjustment Screw
16 Left Hydrostatic Pump Neutral Adjustment Screw
Pump Adjustment Screw Locations
Right Forward Pump Adjustment

Use the left forward pump adjustment screw (9) to set maximum track speed for left forward direction. Use the right forward
pump adjustment screw (7) to set maximum track speed for right forward direction.
To slow track speed, loosen the lock nut and turn the adjustment screw clockwise.
To increase track speed, loosen the lock nut and turn the adjustment screw counterclockwise.
[24] - After adjusting track speed, tighten lock nut to specification.

Pump Adjustment Screw Lock Nut Torque 7.7—10.8 N·m
68—96 lb-in.
[25] -
→NOTE:
Tracking must be verified by driving the machine. If mistracking is more than the width of the machine
per 30.5 m (100 ft) of travel, readjustment of the pump adjustment screws is required.
Repeat procedure with the left and right control levers at full reverse position.
Hydraulic Control Handle Adjustment—Hands Only Machine

This procedure ensures that the control handles are centered, giving equal hydraulic oil flow in all positions.
[3] - Remove footwell to access the hydraulic control valve. See Footwell Removal . (Operator′s Manual.)
[4] -
LEGEND:
Hydraulic Hand Controls

Move each control lever (1 and 2) all the way down and all the way up. Ensure boom spool locks into float detent.
[5] - Confirm that when the handles are returned to neutral position, they are in the center of the operating range.
[6] -
LEGEND:
3 Control Cable (2 each)
4 Control Cable Lock Nut (4 each)
Control Cables and Lock Nuts

If adjustment is needed, locate control cables (3) on hydraulic control valve, loosen control cable lock nuts (4).
[7] - Adjust control cable lock nuts until handle is centered.
[8] - Tighten control cable lock nuts finger tight against cable saddle, then tighten to specification.
Hand Control Cable Lock Nut Torque 27 N·m
240 lb-in.
Park Brake Release Pressure Test

Specifications
SPECIFICATIONS
43°C
110°F
2068 kPa
Brake Release Pressure 20.6 bar
300 psi
1517 kPa
Brake Release Minimum Pressure (minimum) 15.2 bar
220 psi
-6 Tee
Quick Coupler
This procedure tests the park brake release hydraulic pressure. Brakes are applied by internal spring and released with charge
pressure when park brake switch is off and the engine is running.
[1] - Make sure machine charge pressure is correct before testing park brake release pressure. See Charge Pressure Relief
Valve Test . (Group 9025-25.)
[2] -
IMPORTANT:
Operate machine until hydraulic oil reaches specification.

110°F
[5] - Disengage park brake switch.
[6] -
CAUTION:
pressure.
[9] -
→NOTE:
9026-25.)
[10] - Install M8 x 30 cap screws in tab at the rear of both yokes of control levers to secure levers during adjustment
procedure.
[11] -
CAUTION:
[12] -
Park Brake Release Line—332D Shown

LEGEND:
Remove park brake release line (156) at hydrostatic control valve (11). Install a quick coupler (3) for pressure gauge.
HEATING AND AIR CONDITIONING (g) by Belgreen v2.0
[13] - Install a tee in line with a quick coupler.

Tee
-6
Used for testing park brake release pressure.
Quick Coupler
[14] - Connect JT02156A Digital Pressure Temperature Analyzer to quick coupler. See JT02156A Digital Pressure/Temperature
Analyzer Installation . (Group 9025-25.)
JT02156A
[15] - Start engine and run at fast idle, switch park brake to run position. Record pressure gauge.
Brake Release Pressure 2068 kPa
20.6 bar
300 psi
[16] - If pressure reading is within specifications, move right control lever forward and observe that right wheels move freely,
indicating brakes are fully released. Repeat procedure for left side. See Track Speed Test . (Group 9026-25.)
[17] - If pressure is not within specification, check park brake solenoid. See Solenoid Test . (Group 9015-20.)
[18] - If park brake solenoid is functioning correctly and pressure is not within specification remove brake release line at left
hydrostatic motor.
[19] - Cap and plug all openings.
[20] - Start engine and run at fast idle, switch park brake to run position. Record pressure gauge reading.
Brake Release Pressure (minimum) 1517 kPa
15.2 bar
220 psi
[21] - If park brake release pressure meets specification, check left hydrostatic motor brake for leakage.
If park brake release pressure does not meet specification, check right hydrostatic motor brake for leakage. See Hydrostatic
Motor, Park Brake and Gearbox Repair . (Group 0360.)
Section 9031 - HEATING AND AIR CONDITIONING

Table of contents
Air Conditioning System Cycle of Operation ......................................................................................... 1
Air Conditioning and Heater System Component Location ................................................................... 3
Air Conditioning System Does Not Operate Diagnostic Procedure ....................................................... 5
Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure .................................................. 9
Air Conditioner Runs Constantly, Too Cool Diagnostic Procedure ....................................................... 11
Heater System Does Not Operate Diagnostic Procedure .................................................................... 12
Heater Does Not Warm Interior of Cab Diagnostic Process ................................................................ 14
Interior Windows Continue to Fog Diagnostic Procedure .................................................................... 15
Group 25 - Tests ..................................................................................................................................... 16
Refrigerant Cautions and Proper Handling ......................................................................................... 16
Visual Inspection Of Components ....................................................................................................... 17
Refrigerant Leak Testing .................................................................................................................... 19
Air Conditioner Compressor Clutch Test ............................................................................................. 19
Air Conditioning High-Low Pressure Switch Test ................................................................................. 21
Air Conditioner Freeze Control Switch Test ........................................................................................ 23
R134a Refrigerant Cautions ............................................................................................................... 24
R134a Oil Charge Capacity ................................................................................................................. 24
R134a Refrigerant Charge Capacity ................................................................................................... 24
Operating Pressure Diagnostic Chart .................................................................................................. 25

Section 9031 - HEATING AND AIR CONDITIONING Group 05: Theory of Operation

Air Conditioning System Cycle of Operation
Refrigerant System Cycle Of Operation

LEGEND:
1 Evaporator
2 Compressor
3 Condenser
4 Circulation Fan Motor
5 Expansion Valve
6 Receiver-Dryer
7 High Pressure Liquid
8 High Pressure Gas
9 Low Pressure Liquid
10 Low Pressure Gas
11 Air Flow
The compressor (2) is belt driven and engaged by an electro-magnetic clutch. The air conditioning circuit automatically controls
compressor engagement or disengagement when system is in operation.
Compressor draws low pressure gas from evaporator (1) and compresses it into high pressure gas. This causes temperature of
refrigerant to rise higher than that of outside air.
High pressure gas leaves compressor and flows through condenser (3) where heat is removed and transferred to outside air
being drawn through condenser core by engine fan. Cooling refrigerant causes it to condense and refrigerant leaves condenser
as high pressure liquid.
High pressure liquid flows into receiver-dryer (6) where moisture and contaminants (acid, solids, etc.) are removed. Should
moisture be combined with refrigerant, hydrofluoric and hydrochloric acids are formed. These acids are very corrosive to metal
surfaces and leakage will eventually develop. Receiver-dryer also stores refrigerant allowing a longer period of time before
Section 9031 - HEATING AND AIR CONDITIONING Group 15: Diagnostic Information
additional refrigerant is needed. Refrigerant hoses allow a small amount of refrigerant to migrate through their walls.
Refrigerant flows from receiver-dryer through expansion valve (5) to evaporator. Expansion valve senses refrigerant
temperature and pressure to modulate refrigerant flow. Expansion valve changes refrigerant to low pressure liquid entering
evaporator. Actual cooling and drying of cab air takes place at evaporator. Heat absorbed by evaporator and transferred to
refrigerant causes refrigerant to vaporize into low pressure gas. Low pressure gas is drawn from evaporator by compressor and
cycle is repeated.
A freeze control switch senses temperature of evaporator coil through a sensing probe and electronic switch. This prevents the
evaporator from becoming cold enough to freeze moisture that condenses on evaporator coil. Condensed moisture is drained
away through drain tubes in the drain pan under the evaporator.
System pressure is monitored by the high and low pressure switch, located near the receiver-dryer. See Air Conditioning and
Heater System Component Location . (Group 9031-15.) for location of system components. If pressure becomes too high or too
low the switch opens and stops compressor, interrupting the cycle.

Air Conditioning and Heater System Component Location
Heating and Air Conditioning System Component Location

LEGEND:
2 Air Conditioner High Pressure Diagnostic Port
3 Air Conditioner Compressor-to-Condenser High Pressure Line

4 Air Conditioner Condenser
5 Air Conditioner Condenser-to-Receiver-Dryer High Pressure Line
6 Air Conditioner Receiver-Dryer
7 Air Conditioner Receiver-Dryer-to-Expansion Valve High Pressure Line
8 High/Low Pressure Switch
9 Expansion Valve
10 Evaporator
11 Air Conditioner Freeze Control Switch
12 Air Conditioner Low Pressure Diagnostic Port
13 Expansion Valve-to-Air Conditioner Compressor Low Pressure Line
14 Heater Hot Water Feed Line
15 Heater Hot Water Valve
16 Heater Core
17 Heater Hot Water Return Line
Air Conditioning System Does Not Operate

70
Air Conditioning System Does Not Operate Diagnostic Procedure

( 1 ) Accessory Fuse Check
Action:
Remove accessory 20 A fuse (F7). See Fuse and Relay Specifications . (Group 9015-10.)
Check continuity of fuse (F7).
Result:
YES:Go to Blower Motor Fuse Check.

NO:Replace fuse.
( 2 ) Blower Motor Fuse Check
Action:
Remove air conditioning and heater 30 A fuse (F8). See Fuse and Relay Specifications . (Group 9015-10.)
Result:
YES:Go to Accessory Relay Check.

NO:Replace fuse.
( 3 ) Accessory Relay Check
Action:
Remove accessory relay (K4). See Fuse and Relay Specifications . (Group 9015-10.)
Test relay. See Electrical Component Checks . (Group 9015-20.)
Does relay test good?
Result:
YES:Go to Blower Speed Switch Check.

NO:Accessory relay malfunction. Replace relay.
( 4 ) Blower Speed Switch Check
Action:
Check blower speed switch (S9). See Cab Harness (W2) Component Location . (Group 9015-10.)
Check continuity of blower speed switch (S9) in all switch positions. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
Blower Speed Switch Continuity Table
Switch Position Continuity Between Pins
Off No Continuity
Low 1 and Battery Power
Medium 1, 2 and Battery Power
High 1, 2, 3 and Battery Power
Maximum 1, 2, 3, 4 and Battery Power
Is switch operating properly?
Result:
YES:Go to Blower Resistor Check.

NO:Blower speed switch (S9) malfunction. Replace switch.
( 5 ) Blower Resistor Check
Action:
Disconnect blower resistor (R4). See Heater and Air Conditioner Harness (W16) Component Location . (Group 9015-10.)
Measure speed 1 resistance between terminals 2 and 1 on blower resistor (R4).
Compare resistance values to specification.
Blower Resistor (R4) Speed 1 Resistance 2 ohms
Speed 2 Resistance 0.5 ohms
Are all resistance values within specification?
Result:
YES:Go to Blower Motor Check.

NO:Blower resistor (R4) malfunction. Replace resistor.
( 6 ) Blower Motor Check
Action:
Disconnect blower motor (M3). See Heater and Air Conditioner Harness (W16) Component Location . (Group 9015-10.)
Supply 12 volts and ground to blower motor (M3).
Does motor run?
Result:
YES:Go to Air Conditioner Switch Check.

NO:Motor malfunction. Replace blower motor (M3).
( 7 ) Air Conditioner Switch Check
Action:
Check air conditioner switch (S19). See Cab Harness (W2) Component Location . (Group 9015-10.)
Check for continuity between pins 2 and 3.
Air Conditioner Switch Continuity Table
Off No Continuity
On Continuity Between Pins 2 and 3
Result:
YES:Go to Air Conditioner Compressor Clutch Relay Check.

NO:Air conditioner switch (S19) malfunction. Replace switch.
( 8 ) Air Conditioner Compressor Clutch Relay Check
Action:
Remove air conditioner compressor clutch relay (K7). See Fuse and Relay Specifications . (Group 9015-10.)
Result:
YES:Go to Freeze Control Switch Check.

NO:Air conditioner compressor clutch relay malfunction. Replace relay.
( 9 ) Freeze Control Switch Check
Action:
Test air conditioner freeze control switch (B10). See Air Conditioner Freeze Control Switch Test . (Group 9031-25.)
Does air conditioner freeze control switch (B10) test good?
Result:
YES:Go to Air Conditioner High-Low Pressure Switch.

NO:Freeze control switch (B10) malfunction. Replace switch.
( 10 ) Air Conditioner High-Low Pressure Switch
Action:
Test air conditioner high-low pressure switch (B9). See Air Conditioning High-Low Pressure Switch Test . (Group 9031-25.)
Does air conditioner high-low pressure switch (B9) test good?
Result:
YES:Go to Air Conditioner Compressor Clutch Check.

NO:Air conditioner high-low pressure switch (B9) malfunction. Replace switch.
( 11 ) Air Conditioner Compressor Clutch Check
Action:
Disconnect air conditioner compressor clutch (Y13) wire connector. See Engine Harness (W1) Component Location . (Group
9015-10.)
Supply 12 volts and ground to air conditioner compressor clutch (Y13).
Air conditioner clutch solenoid should “click” and engage.
Does air conditioner compressor clutch (Y13) solenoid “click” and engage when 12 volts are applied?
Result:
YES:Go to Wiring Harness Check.

NO:Air conditioner compressor clutch (Y13) malfunction. Replace compressor clutch.
( 12 ) Wiring Harness Check
Action:
Check heater and air conditioning system wiring for open and short circuits. For schematic, See System Functional Schematic .
(Group 9015-10.)
For wiring diagrams, see Engine Harness (W1) Component Location (Group 9015-10), see Cab Harness (W2) Component
Location (Group 9015-10) and see Heater and Air Conditioner Harness (W16) Component Location . (Group 9015-10.)
Does heater and air conditioning system wiring contain open or short circuits?
Result:
YES:Repair or replace heater and air conditioning system wiring.

NO:Checks complete.
Air Conditioning Does Not Cool Interior of Cab

70
Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure

( 1 ) Fresh Air Filter Restricted
Action:
Check fresh air filter for debris or air flow restrictions.

Is fresh air filter clogged?
Result:
YES:Clean or replace fresh air filter.

NO:Go to Recirculation Air Filter Restricted.
( 2 ) Recirculation Air Filter Restricted
Action:
Check recirculation air filter for debris or air flow restrictions.

Is recirculation air filter clogged?
Result:
YES:Clean or replace recirculation air filter.

NO:Go to Condenser Restriction Check.
( 3 ) Condenser Restriction Check
Action:
Check condenser fins for air flow restrictions. See Air Conditioning and Heater System Component Location . (Group 9031-15.)
Are condenser fins clogged with debris?
Result:
YES:Clean condenser fins.

NO:Go to Refrigerant Hose Restriction Check.
( 4 ) Refrigerant Hose Restriction Check
Action:
Check refrigerant hoses for kinks, pinches, or collapsed sections. See Air Conditioning and Heater System Component Location
. (Group 9031-15.)
Are any hoses kinked, pinched, or collapsed?
Result:
YES:Re-route or re-index hoses. Replace kinked or collapsed hoses.

NO:Go to Blower Resistor Check.
Action:

Result:

Action:
Does motor run?
Result:
YES:Go to Compressor Belt Check.

( 7 ) Compressor Belt Check
Action:
Check engine serpentine belt.

Is belt tension OK?
Result:
YES:Go to Cab Seals Check.

NO:Adjust or replace belt.
( 8 ) Cab Seals Check
Action:
Check windows and door to make sure seals are good.

Are seals on all windows and door functioning properly?
Result:
YES:Go to System Refrigerant (R134a) Leak Check.

NO:Repair or replace malfunctioning seals.
( 9 ) System Refrigerant (R134a) Leak Check
Action:
Check for leaks in refrigerant system. See Refrigerant Leak Testing . (Group 9031-25.)
Are any leaks present in refrigerant system?
Result:
YES:Repair or replace hoses and recharge system. See Charge R134a System . (Group 1830.)
NO:Charge system. See Charge R134a System . (Group 1830.) Go to Evaporator Core Fins Check.
( 10 ) Evaporator Core Fins Check
Action:
Check evaporator core fins for frosting or freezing.

Is there any ice or frost on evaporator fins?
Result:
YES:Temperature probe for the freeze control switch is not positioned correctly in evaporator core. Reposition probe in
evaporator core.
NO:Checks complete.
Air Conditioner Runs Constantly, Too Cool
70
Air Conditioner Runs Constantly, Too Cool Diagnostic Procedure

( 1 ) Evaporator Core Component Check
Action:
Check evaporator core fins for frosting or freezing.

Is there any ice or frost on evaporator fins?
Result:
YES:Temperature probe for the freeze control switch is not positioned correctly in evaporator core. Reposition probe in
evaporator core.
NO:Compressor clutch running constantly. Go to Air Conditioner Freeze Control Switch Check.
( 2 ) Air Conditioner Freeze Control Switch Check
Action:
Remove air conditioner freeze control switch (B10). See Heater and Air Conditioner Harness (W16) Component Location .
(Group 9015-10.)
Check air conditioner freeze control switch (B10). See Air Conditioner Freeze Control Switch Test . (Group 9031-25.)
Does air conditioner freeze control switch (B10) test good?
Result:
YES:Go to Heater Hot Water Valve Check.

NO:Air conditioner freeze control switch (B10) malfunction. Replace switch.
( 3 ) Heater Hot Water Valve Check
Action:
Inspect heater hot water valve actuator. See Air Conditioning and Heater System Component Location . (Group 9031-15.)
Is heater hot water valve actuator functioning properly?
Result:
NO:Replace heater hot water valve actuator.
Heater System Does Not Operate

70
Heater System Does Not Operate Diagnostic Procedure

( 1 ) Accessory Fuse Check
Action:
Remove accessory 20 A fuse (F7). See Fuse and Relay Specifications . (Group 9015-10.)
Result:
YES:Go to Blower Motor Fuse Check.

NO:Replace fuse.
( 2 ) Blower Motor Fuse Check
Action:
Remove air conditioning and heater 30 A fuse (F8). See Fuse and Relay Specifications . (Group 9015-10.)
Result:
YES:Go to Accessory Relay Check.

NO:Replace fuse.
( 3 ) Accessory Relay Check
Action:
Remove accessory relay (K4). See Fuse and Relay Specifications . (Group 9015-10.)
Result:
YES:Go to Blower Speed Switch Check.

NO:Accessory relay malfunction. Replace relay.
( 4 ) Blower Speed Switch Check
Action:
Check blower speed switch (S9). See Cab Harness (W2) Component Location . (Group 9015-10.)
Check continuity of blower speed switch (S9) in all switch positions. See Cab Harness (W2) Wiring Diagram . (Group 9015-10.)
Blower Speed Switch Continuity Table
Off No Continuity
Low 1 and Battery Power
Medium 1, 2 and Battery Power
High 1, 2, 3 and Battery Power
Maximum 1, 2, 3, 4 and Battery Power
Result:
YES:Go to Blower Resistor Check.

NO:Blower speed switch (S9) malfunction. Replace switch.
Action:
Result:

Action:
Does motor run?
Result:
YES:Go to Wiring Harness Check.

( 7 ) Wiring Harness Check
Action:
Check heater and air conditioning system wiring for open and short circuits. For schematic, See System Functional Schematic .
(Group 9015-10.)
For wiring diagrams, see Engine Harness (W1) Wiring Diagram (Group 9015-10), see Cab Harness (W2) Wiring Diagram (Group
9015-10) and see Heater and Air Conditioner Harness (W16) Component Location . (Group 9015-10.)
Does heater and air conditioning system wiring contain open or short circuits?
Result:
YES:Repair or replace heater and air conditioner wiring.

NO:Checks complete.
Heater Does Not Warm Interior of Cab

70
Heater Does Not Warm Interior of Cab Diagnostic Process

Action:

Result:

NO:Go to Fresh Air Filter Restricted.
( 2 ) Fresh Air Filter Restricted
Action:

Result:

NO:Go to Hot Water Hose Restriction Check.
( 3 ) Hot Water Hose Restriction Check
Action:
Check hot water hoses for kinks, pinches, or collapsed sections. See Air Conditioning and Heater System Component Location .
(Group 9031-15.)
Are hoses kinked, pinched, or collapsed?
Result:
YES:Re-route or re-index hoses. Replace kinked or collapsed hoses.

NO:Go to Condenser Core and Evaporator Core Air Flow Restriction Check.
( 4 ) Condenser Core and Evaporator Core Air Flow Restriction Check
Action:
Check condenser core and evaporator core fins.

Are the condenser core or evaporator core fins clogged with debris?
Result:
YES:Clean condenser core and evaporator core fins.

NO:Go to Blower Motor Check.
Action:
Does motor run?
Section 9031 - HEATING AND AIR CONDITIONING Group 25: Tests
Result:
YES:Go to Heater Hot Water Valve Check.

( 6 ) Heater Hot Water Valve Check
Action:
Inspect heater hot water valve actuator. See Air Conditioning and Heater System Component Location . (Group 9031-15.)
Is heater hot water valve actuator functioning properly?
Result:
NO:Replace heater hot water valve actuator.
Interior Windows Continue to Fog
70
Interior Windows Continue to Fog Diagnostic Procedure

( 1 ) Air Conditioning System Off Check
Action:
Check air conditioner switch (S19). See Cab Harness (W2) Component Location . (Group 9015-10.)
Is air conditioner switch in the ON position?
Result:
YES:Go to Fresh Air Filter Restricted Check.

NO:Push air conditioner switch to the ON position.
( 2 ) Fresh Air Filter Restriction Check
Action:

Result:

NO:Go to Recirculation Air Filter Restricted.
Action:

Result:

NO:Checks complete.
Group 25 - Tests
Refrigerant Cautions and Proper Handling
CAUTION:
DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on
contact. Wear goggles, gloves and protective clothing.
If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on
affected area. Go to a physician or hospital immediately for treatment.
DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc,
electric heating element and lighted smoking materials.
DO NOT heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will develop high
pressure which can burst the container.
Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.
DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear
gloves.
If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or
hospital immediately for treatment.
IMPORTANT:
To meet government standards relating to the use of refrigerants, R134a is used in the air conditioning
system. Because it does not contain chlorine, R134a is not detrimental to the ozone in the atmosphere.
However, it is illegal to discharge any refrigerant into the atmosphere. It must be recovered using the
appropriate recovery stations.
Use correct refrigerant recovery, recycling and charging stations. Never mix refrigerants, hoses, fittings,
components or refrigerant oils.
Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause
system damage and contaminate recovery, recycling and charging station equipment. Care must be
taken to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant
systems. Refrigerant should be tested for type and purity before recovery, recycling or charging of
system. JT02167A refrigerant test instrument should be used before any testing or repair to system is
performed.
Prism Pro Refrigerant Identification Instrument

JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of air conditioning systems.
Air Conditioner and Heater Operational Checks

→NOTE:
Visually inspect components prior to performing any diagnostics and tests. See Visual Inspection of
Components . (Group 9031-25.)
Visual Inspection Of Components

( 1 ) Lines and Hoses Check
Action:
Inspect all lines and hoses.

sss:
Are all lines and hoses straight and in good condition, NOT kinked, worn from rubbing, or weather checked?
sss:
Are hose and line connections clean and NOT showing signs of leakage, such as dirt, oil, or refrigerant dye?
sss:
Are all hose and line clamps in place and tight, with cushions or rubber inserts in place to prevent crushing or scuffing hoses or
lines?
Result:

NO:Reposition hoses and lines as necessary. Replace, adjust, and tighten clamps as necessary. Note any hoses or lines that
will require replacement.
( 2 ) Air Conditioner Compressor Check
Action:
Inspect compressor.
sss:
Is belt properly tensioned on pulley?
sss:
Is belt in good condition, NOT frayed, worn, or glazed?
sss:
Is belt tensioner in good condition, NOT worn or damaged?
sss:
Is compressor pulley in good condition, and properly aligned with belt drive pulley on engine?
sss:
Are compressor mounting brackets in good condition, and is mounting hardware properly tightened?
sss:
Are electrical connections to compressor clean and tight? Is wiring in good condition?
Result:

NO:Note any components that will require repair or replacement.
( 3 ) Condenser Check
Action:
Inspect condenser core.
sss:
Is core free of dirt and debris?
sss:
Is core NOT showing signs of leakage, such as dirt, oil, or refrigerant dye?
sss:
Are fins of core straight, NOT bent or damaged?
Result:

NO:Clean and straighten fins if necessary. Note any components that will require repair or replacement.
( 4 ) Engine Fan Check
Action:
Inspect engine fan.

sss:
Are fan blades in good condition, NOT worn, bent, broken, or missing?
sss:
Is fan securely installed?
Result:

NO:Note any components that will require repair or replacement.
( 5 ) Heater/Evaporator Core Check
Action:
Inspect heater/evaporator core.

sss:
Is core free of dirt and debris?
sss:
Is core NOT showing signs of leakage, such as dirt, oil, or refrigerant dye?
sss:
Are fins of core straight, NOT bent or damaged?
sss:
Is condensation drain tube attached and in good condition, NOT kinked, damaged, or clogged?
Result:

NO:Clean and straighten fins if necessary. Note any components that will require repair or replacement.
( 6 ) Freeze Control Switch Probe Check
Action:
Inspect freeze control switch probe.

sss:
Are wires from probe to switch worn or broken?
sss:
Is probe properly positioned and securely inserted in evaporator core?
Result:

NO:If probe wire is worn or broken, replace freeze control switch.
NO:If probe is improperly positioned, test freeze control switch. See Air Conditioner Freeze Control Switch Test . (Group
9031-25.)
( 7 ) Cab Air Filter and Recirculation Air Filter Check
Action:
Inspect both cab air filter and recirculation air filter.

sss:
Are filters clean and free of debris?
Result:

NO:Clean or replace cab air filter and/or recirculation air filter.
( 8 ) Cab Door and Windows Check
Action:
Open and close cab door and windows. Inspect seals.

sss:
Are seals present, properly installed, and in good condition?
sss:
Do door and windows contact seals evenly?
Result:
YES:Check complete.
NO:Adjust door and windows if necessary. Replace components as necessary.
Refrigerant Leak Testing

Specifications
SPECIFICATIONS
25 mm per second
Move Leak Detector Speed
1 in. per second
Inspect all lines, fittings, and components for oily or dusty spots. When refrigerant leaks from the system, a small amount
of oil is carried out with it.
A soap and water solution can be sprayed on the components in the system to form bubbles at the source of the leak.
If a leak detector is used, move the leak detector probe under the hoses and around the connections at a rate of 25 mm
(1 in.) per second.
Move Leak Detector Speed 25 mm per second
1 in. per second
Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.
Air Conditioner Compressor Clutch Test

[1] - Disconnect clutch solenoid wire connector.
[2] -
LEGEND:
2 Air Conditioner Compressor Clutch Wire Connector
Air Conditioner Compressor Clutch Test

Connect battery voltage to engage compressor clutch. Connect positive (+) terminal to clutch wire connector (2). Connect
negative (-) terminal to compressor housing.
[3] - Air conditioner compressor clutch solenoid should “click” and engage.
[4] - If air conditioner compressor clutch does not “click” or engage, replace compressor. See Air Conditioner Compressor
Remove and Install . (Group 1830.)
[5] - If air conditioner compressor clutch “clicks” and engages, check wiring harness and air conditioner high/low pressure
switch. See Cab Harness (W2) Wiring Diagram (Group 9015-10) and see Air Conditioning High-Low Pressure Switch Test .
(Group 9031-25.)
Air Conditioning High-Low Pressure Switch Test
Pressure Switch
Specifications
SPECIFICATIONS
137.9—227.5 kPa
Low Pressure Opening Pressure 1.379—2.275 bar
20—33 psi
158.6—255.1 kPa
Low Pressure (normally open) Closing Pressure 1.586—2.551 bar
23—37 psi
2620—2895 kPa
High Pressure Opening Pressure 26.20—28.95 bar
380—420 psi
1379—2068 kPa
High Pressure (normally closed) Closing Pressure 13.79—20.68 bar
200—300 psi
Essential Tools
ESSENTIAL TOOLS
JT02148 Straight Connector
Multimeter
→NOTE:
High-low pressure switch is normally open when removed from machine. When installed, the switch
becomes closed from normal system pressure.
[1] - Turn key switch on but do not start engine. Turn blower switch on. Turn temperature control switch to the maximum
cooling position.
[2] - Disconnect and connect low pressure switch at harness connector. Compressor clutch must engage and disengage (click).
→NOTE:
A valve is installed behind the high-low pressure switch to prevent the system from discharging when
switch is removed.
[3] - Disconnect harness from high-low pressure switch and remove switch from line. Connect high-low pressure switch to
harness. Compressor clutch must not engage (click).
Low Pressure Opening Pressure 137.9—227.5 kPa
1.379—2.275 bar
20—33 psi
Low Pressure (normally open) Closing Pressure 158.6—255.1 kPa
1.586—2.551 bar
23—37 psi
Straight Connector
JT02148
Switch Testing
[4] - 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 using JT02148 Straight Connector.
Multimeter
For High Pressure Switch Test
[5] - 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.
[6] - Connect a portable pressure source, such as dry nitrogen, to switch.

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
[7] - Switch must have continuity between terminals until pressure increases to switch opening pressure specification.
Straight Connector For Switch Testing
JT02148
For Switch Testing
[8] - Slowly release pressure. Switch must not have continuity until pressure decreases to switch closing pressure
specification.
Multimeter
For High Pressure Switch Test
[9] - 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.
Air Conditioner Freeze Control Switch Test

Specifications
SPECIFICATIONS
-1.6—0.6°C
Freeze Control Switch Opening (cut-out) Temperature
29—33°F
2.8—5.0°C
Freeze Control Switch Closing (cut-in) Temperature
37—41°F
JT05791A Digital Multimeter
[1] -
Air Conditioner Freeze Control Switch Connector

Disconnect and remove freeze control switch (B10). See Air Conditioning and Heater System Component Location . (Group
9031-15.)
[2] - Apply 12 volts to pin A and ground pin C on air conditioner freeze control switch connector.
[3] - Using a multimeter, measure voltage at pin B; make sure negative lead is grounded. If temperature is above 5°C (41°F),
meter reading should be 12 volts.
Digital Multimeter
JT05791A
Measures Resistance
[4] - Place end of probe into an ice and saltwater solution. When opening (cut-out) temperature specification is reached or
exceeded, meter reading should be zero volts.
Freeze Control Switch Opening (cut-out) Temperature -1.6—0.6°C
29—33°F
[5] - Increase temperature of solution. When closing (cut-in) temperature specification is reached or exceeded, meter reading
should be 12 volts.
Freeze Control Switch Closing (cut-in) Temperature 2.8—5.0°C
37—41°F
[6] - If switch does not operate within specifications, replace air conditioner freeze control switch.
R134a Refrigerant Cautions

Specifications
SPECIFICATIONS
52°C
Maximum Amount To Heat Refrigerant In Closed Container Temperature
125°F
CAUTION:
DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on
contact. Wear goggles, gloves and protective clothing.
If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on
affected area. Go to a physician or hospital immediately for treatment.
DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc,
electric heating element and lighted smoking materials.
DO NOT heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will develop high
pressure which can burst the container.
Maximum Amount To Heat Refrigerant In Closed Container Temperature 52°C
125°F
Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.
DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear
gloves.
If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or
hospital immediately for treatment.
R134a Oil Charge Capacity

R134a Oil Charge Capacity 217.4 mL
7.35 fl. oz.
R134a Refrigerant Charge Capacity

R134a Refrigerant Charge Capacity 1.36 kg
3.0 lb.
Operating Pressure Diagnostic Chart

→NOTE:
Inspection of the sight glass will not give proper indicators of air conditioning concerns on R134a
systems.
Operating Pressure Diagnostic Chart
OPERATING PRESSURE DIAGNOSTIC CHART
Low Side High Side

Problem Solution
Pressure Pressure
Leak in system. Do leak test. Add refrigerant. Normal migration through hoses. Add
Low Low or Normal Loss of refrigerant.
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.
Restriction in system:
1. Between compressor and
condenser.
Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove
Low Low or Normal 2. Inside condenser.
refrigerant by recovery method. Inspect and clean each component.
3. Between condenser and receiver-
dryer.
4. Inside receiver-dryer.
Low Low or Normal Blower motor running too slow. Check for motor shaft binding or defective electrical connections.
Evaporator core dirty or air flow

Low Low or Normal Clean evaporator and straighten fins.
through evaporator restricted.
Low Low or Normal Expansion valve malfunction. Replace expansion valve.
1. Between receiver-dryer and
expansion valve.
Low Low or Normal 2. Between expansion valve and
evaporator.
3. Between evaporator and
compressor.
Remove refrigerant using recovery method, evacuate and charge the system. See
Low Low or Normal Moisture in system. Recover R134a Refrigerant , see Evacuate R134a System , and see Charge R134a
System . (Group 1830.)
condenser.
2. Inside condenser.
Low High 3. Between condenser and receiver-
dryer.
5. Between receiver-dryer and
expansion valve.
Normal Normal Heater valve not closing. Close heater shutoff valve on engine block or clamp heater hoses shut.
Normal Normal Expansion valve malfunction. Replace expansion valve.
Moisture in system (intermittent
Normal Normal Recover R134a Refrigerant , see Evacuate R134a System , and see Charge R134a
cooling below 27°C [80°F] ambient).
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. Recover R134a Refrigerant , see Evacuate R134a System , and see Charge R134a
Restricted air flow through condenser

Normal High Inspect for debris. Straighten fins.
or radiator.
Start engine and run at fast idle. Operate air conditioner at maximum cooling. Remove
Normal High Overcharge of refrigerant. refrigerant from low-side of system using recovery operation until bubbles appear in
sight glass. Add 0.7 kg (1.5 lb) of refrigerant vapor through low-side valve.
Normal High Expansion valve malfunction. Replace expansion valve.
DEALER FABRICATED TOOLS (g) by Belgreen v2.0
OPERATING PRESSURE DIAGNOSTIC CHART
Low Side High Side

Problem Solution
Pressure Pressure
condenser.
Normal High 2. Inside condenser.
dryer.
condenser.
Normal High 2. Inside condenser.
dryer.
High Low Compressor belt loose. Tighten belt.
Check for battery voltage at compressor clutch with clutch engaged. Clean electrical
High Low Compressor clutch slipping.
connections or replace relay.
High Low Compressor clutch slipping. Inspect and repair clutch.
High Low Compressor failure. Test compressor efficiency. (Group 1830.)
High Normal Expansion valve malfunction. Replace expansion valve.
Restricted air flow through condenser

High High Inspect for debris. Straighten fins.
or radiator.
High High Expansion valve malfunction. Replace expansion valve.
Start engine and run at fast idle. Operate air conditioner at maximum cooling. Remove
High High Overcharge of refrigerant. 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 vapor through low-side valve.
High High Restriction in system.
High High Air in system. Recover R134a Refrigerant , see Evacuate R134a System , and see Charge R134a
condenser.
High High 2. Inside condenser.
dryer.
Section 9900 - DEALER FABRICATED TOOLS

Table of contents
Group 99 - Dealer Fabricated Tools ...................................................................................................... 1
DFT1325 Solenoid Power Harness ........................................................................................................ 1

Section 9900 - DEALER FABRICATED TOOLS Group 99: Dealer Fabricated Tools
Group 99 - Dealer Fabricated Tools


Materials Required:
Spring Clip (2 used)

DT06-2S DEUTSCH ™ 2-pin Connector
244 cm (96 in.) 16 gauge Red Wire
244 cm (96 in.) 16 gauge Black Wire
221 cm (87 in.) Wire Wrap
The solenoid power harness is used to energize the fan bypass solenoid after installing a new fan bypass valve. This procedure
is required to remove air from the solenoid valve to insure correct valve operation.
The solenoid power harness is also used to energize the park brake solenoid on electrohydraulic (EH) control machines when
adjusting the hydrostatic pump mechanical neutral position.
Assemble harness:
[1] - Install spring clips to one end of black and red wires.
[2] - Load wires into Deutsch connector: Red wire in pin 1 and black wire in pin 2.
[3] - Remove locking clip from connector to make it easier to remove connector from solenoid during use.
[4] - Install wire wrap on wires, leaving wires exposed on spring clip end for connecting to battery terminals.

TM 11446

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329D and 333D Skid Steer

Loader (Manual Controls)

OPERATION AND TEST MANUAL

Manual Controls models 329D, 333D

For complete service information also see:

John Deere Commercial Worksite Products

<- Go to Global Table of contents TM11446-OPERATION AND TEST MANUAL

<- Go to Global Table of contents TM11446-OPERATION AND TEST MANUAL

Technical Information Feedback Form

Technical Manual Fax

SEND TO: John Deere Dubuque Works

18600 South John Deere Road

Attn: Publications, Dept. 324

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

Section 9000 - GENERAL INFORMATION

<- Go to Global Table of contents TM11446-OPERATION AND TEST MANUAL

Safety Alert Symbols

Safety Alert Symbols

Follow Safety Instructions

this operator′s manual.

Operate Only If Qualiﬁed

Wear Protective Clothing

Avoid Unauthorized Machine Modiﬁcations

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

Stay Clear of Moving Parts

Stay Clear Of Moving Parts

Entanglements in moving parts can cause serious injury.

Avoid High-Pressure Fluids

Avoid High-Pressure Oils

Avoid High Pressure Oils

Avoid High-Pressure Oils

Work In Ventilated Area

Engine exhaust fumes

Handle Fuel Safely

Clean Machine Regularly

Carry A Fire Extinguisher

Prevent Battery Explosions

Handle Chemical Products Safely

Material Safety Data Sheet

Decommissioning: Proper Recycling and Disposal of Fluids and

Prepare for Emergencies

First Aid Kit

Be prepared if an emergency occurs or a ﬁre starts.

Clean Debris from Machine

Clean Debris From Machine

Use Steps and Handholds Correctly

Use Handholds and Steps

Start Only From Operator′s Seat

Operate Only From Operators Seat

Use and Maintain Seat Belt

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Park Brake Switch

Lower equipment to the ground

Avoid Work Site Hazards

Contact with electrical lines

Operate on Solid Footing

Do not stand on track.

Keep Riders Oﬀ Machine

Keep Riders Oﬀ Machine

Only allow operator on machine.

Avoid Backover Accidents

Avoid Backover Accidents