John Deere 6020 6120 6220 6320 6420 6420S 6520 6620 6820 6920 6920S Tractors and SE Tractor 6020 612

6020 to 6920S Tractors and SE Tractors Diagnostics

TECHNICAL MANUAL 6020 to 6920S Tractors and SE Tractors Diagnostics TM4726 01NOV03 (ENGLISCH)

For complete service information also see: 6020 to 6920S Tractors and SE Tractors Operation and Tests . . . . . . . . . . . . . . . . . . .

6020 to 6620 Tractors and SE Tractors Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tractors 6820, 6920 and 6920S Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Wheel Drive Axles - AS and MS Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Wheel Drive Axles (700 Series) . . . . .

POWERTECH Diesel Engines . . . . . . . . . . .

Mechanical Fuel Injection Systems . . . . . . .

Electronic Fuel Injection Systems (Level 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Fuel Injection Systems (Level 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Fuel Injection Systems (Level 11). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Fuel Injection Systems (Level 12). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternators and Starting Motors (available in English only). . . . . . . . . . . . . . .

TM4741 TM4750 TM4756 CTM4687 CTM4820 CTM104 CTM207 CTM170 CTM284 CTM220 CTM331 CTM77

John Deere Werke Mannheim European Version Printed in Germany

Introduction Foreword This diagnostics manual is valid for the following tractor types: 6020, 6120, 6220, 6320, 6420, 6420S, 6520, 6620, 6820, 6920 and 6920S. SE tractors: 6020, 6120, 6220, 6320, 6420 and 6520.

This manual is written for an experienced technician.

Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

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

Technical Manuals are 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.

LX24888,0000410 –19–01OCT02–1/1

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Contents 210

SECTION 210—GENERAL INFORMATION Group 05—Safety Information SECTION 211—DIAGNOSTIC TROUBLE CODES Group ATC—ATC Diagnostic Trouble Codes Group BCU—BCU Diagnostic Trouble Codes Group BIF—BIF Diagnostic Trouble Codes Group ECU—ECU Diagnostic Trouble Codes Group EPC—EPC Diagnostic Trouble Codes Group JDL—JDL Diagnostic Trouble Codes Group PLC—PLC Diagnostic Trouble Codes Group PRF—PRF Diagnostic Trouble Codes Group SFA—SFA Diagnostic Trouble Codes Group SIC—SIC Diagnostic Trouble Codes Group SSU—SSU Diagnostic Trouble Codes Group TCU—TCU Diagnostic Trouble Codes Group TEC—TEC Diagnostic Trouble Codes Group UIC—UIC Diagnostic Trouble Codes

211

212

213

SECTION 212—OBSERVABLE SYMPTOMS Group 20—Engine Group 40—Electrical System Group 50—SyncroPlus Transmission Group 51—Power Reverser Transmission Group 53—AutoPowr/IVT Transmission Group 55—PowrQuad, PowrQuad Plus and AutoQuad Transmissions Group 56—Drive Systems Group 60—Steering and Brakes Group 70—Hydraulic System Group 90—Operator’s Cab

INDX

SECTION 213—SYSTEM DIAGNOSTICS Group 45—Electronics

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT  2003 DEERE & COMPANY European Office Mannheim All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright  2002, 2001

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211

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210

Section 210

GENERAL INFORMATION Contents Page

Group 05—Safety Information Recognize Safety Information . . . . . . . . . . . . .210-05-1 “Important” - Information . . . . . . . . . . . . . . . . .210-05-1 “Note” - Information . . . . . . . . . . . . . . . . . . . . .210-05-1 Prevent Machine Runaway . . . . . . . . . . . . . . .210-05-1 Handle Fluids Safely—Avoid Fires . . . . . . . . .210-05-2 Prevent Battery Explosions . . . . . . . . . . . . . . .210-05-2 Prepare for Emergencies. . . . . . . . . . . . . . . . .210-05-2 Prevent Acid Burns . . . . . . . . . . . . . . . . . . . . .210-05-3 Avoid High-Pressure Fluids . . . . . . . . . . . . . . .210-05-4 Service Cooling System Safely . . . . . . . . . . . .210-05-4 Remove Paint Before Welding or Heating . . . .210-05-5 Avoid Heating Near Pressurized Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210-05-5 Work In Ventilated Area . . . . . . . . . . . . . . . . .210-05-6 Wear Protective Clothing. . . . . . . . . . . . . . . . .210-05-6 Practice Safe Maintenance . . . . . . . . . . . . . . .210-05-7 Park Machine Safely . . . . . . . . . . . . . . . . . . . .210-05-7 Use Proper Lifting Equipment . . . . . . . . . . . . .210-05-8 Construct Dealer-Made Tools Safely . . . . . . . .210-05-8 Support Machine Properly . . . . . . . . . . . . . . . .210-05-8 Work in Clean Area. . . . . . . . . . . . . . . . . . . . .210-05-9 Illuminate Work Area Safely . . . . . . . . . . . . . .210-05-9 Service Machines Safely . . . . . . . . . . . . . . . . .210-05-9 Use Proper Tools . . . . . . . . . . . . . . . . . . . . .210-05-10 Service Tires Safely . . . . . . . . . . . . . . . . . . .210-05-10 Service Front-Wheel Drive Tractor Safely . . .210-05-11 Safety Information - Air Brake System. . . . . .210-05-11 Avoid Eye Contact With Radar . . . . . . . . . . .210-05-12 Keep ROPS Installed Properly . . . . . . . . . . .210-05-12 Replace Safety Signs . . . . . . . . . . . . . . . . . .210-05-12 Dispose of Waste Properly . . . . . . . . . . . . . .210-05-13 Live With Safety . . . . . . . . . . . . . . . . . . . . . .210-05-13 Safety Measures on Electronic Control Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210-05-14

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Contents 210

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Group 05

Safety Information 210 05 1

Recognize Safety Information

T81389

Follow recommended precautions and safe operating practices.

–UN–07DEC88

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

DX,ALERT –19–29SEP98–1/1

“Important” - Information Information marked as IMPORTANT points out problems that may lead to machine damage. By following the directions given, these problems can be avoided.

LX,CRA05 002885 –19–09APR92–1/1

“Note” - Information When marked with NOTE the information given is more detailed or contains restrictions to directions given previously. On the other hand useful information may be given belonging to certain instructions without being directly connected to them.

LX,CRA05 002886 –19–09APR92–1/1

Prevent Machine Runaway Avoid possible injury or death from machinery runaway.

TS177

NEVER start engine while standing on ground. Start engine only from operator’s seat, with transmission in neutral or park.

–UN–11JAN89

Do not start engine by shorting across starter terminals.

Machine will start in gear if normal circuitry is bypassed.

DX,BYPAS1 –19–29SEP98–1/1

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Safety Information

Handle Fluids Safely—Avoid Fires

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

TS227

Do not store oily rags; they can ignite and burn spontaneously.

–UN–23AUG88

When you work around fuel, do not smoke or work near heaters or other fire hazards.

DX,FLAME –19–29SEP98–1/1

Prevent Battery Explosions

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

TS204

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

–UN–23AUG88

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

DX,SPARKS –19–03MAR93–1/1

Prepare for Emergencies Be prepared if a fire starts.

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

–UN–23AUG88

Keep a first aid kit and fire extinguisher handy.

TS291

210 05 2

DX,FIRE2 –19–03MAR93–1/1

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Safety Information 210 05 3

Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: 1.

2.

3.

4.

5.

Filling batteries in a well-ventilated area.

Wearing eye protection and rubber gloves.

Avoiding breathing fumes when electrolyte is added.

Avoiding spilling or dripping electrolyte.

Use proper jump start procedure.

If you spill acid on yourself:

–UN–23AUG88

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed:

TS203

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3. Get medical attention immediately.

DX,POISON –19–21APR93–1/1

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Safety Information

Avoid High-Pressure Fluids

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

X9811

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

–UN–23AUG88

Escaping fluid under pressure can penetrate the skin causing serious injury.

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 from Deere & Company Medical Department in Moline, Illinois, U.S.A.

DX,FLUID –19–03MAR93–1/1

Service Cooling System Safely

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.

–UN–23AUG88

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

TS281

210 05 4

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Safety Information 210 05 5

Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust.

• 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.

TS220

Remove paint before heating:

–UN–23AUG88

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Do not use a chlorinated solvent in areas where welding will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away.

Dispose of paint and solvent properly.

DX,PAINT –19–24JUL02–1/1

TS953

Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

–UN–15MAY90

Avoid Heating Near Pressurized Fluid Lines

DX,TORCH –19–03MAR93–1/1

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Safety Information

Work In Ventilated Area

TS220

If you do not have an exhaust pipe extension, open the doors and get outside air into the area

–UN–23AUG88

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.

DX,AIR –19–17FEB99–1/1

Wear Protective Clothing

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.

–UN–23AUG88

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

TS206

210 05 6

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

DX,WEAR –19–10SEP90–1/1

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Safety Information 210 05 7

Practice Safe Maintenance Understand service procedure before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.

Securely support any machine elements that must be raised for service work.

On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.

TS218

On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.

–UN–23AUG88

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris.

DX,SERV –19–17FEB99–1/1

Park Machine Safely

Lower all equipment to the ground.

Stop the engine and remove the key.

Disconnect the battery ground strap.

Hang a "DO NOT OPERATE" tag in operator station.

TS230

• • • •

–UN–24MAY89

Before working on the machine:

DX,PARK –19–04JUN90–1/1

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Safety Information

Use Proper Lifting Equipment Lifting heavy components incorrectly can cause severe injury or machine damage.

TS226

–UN–23AUG88

Follow recommended procedure for removal and installation of components in the manual.

DX,LIFT –19–04JUN90–1/1

Construct Dealer-Made Tools Safely

LX1016749

Do not weld tools unless you have the proper equipment and experience to perform the job.

–UN–01JUL97

Faulty or broken tools can result in serious injury. When constructing tools, use proper, quality materials, and good workmanship.

DX,SAFE,TOOLS –19–10OCT97–1/1

Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

Follow recommended procedures in this manual.

–UN–23AUG88

Support Machine Properly

TS229

210 05 8

When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator’s manual.

DX,LOWER –19–24FEB00–1/1

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Safety Information 210 05 9

Work in Clean Area

Clean work area and machine.

Make sure you have all necessary tools to do your job.

Have the right parts on hand.

Read all instructions thoroughly; do not attempt shortcuts.

T6642EJ

• • • •

–UN–18OCT88

Before starting a job:

DX,CLEAN –19–04JUN90–1/1

TS223

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage.

The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

–UN–23AUG88

Illuminate Work Area Safely

DX,LIGHT –19–04JUN90–1/1

Service Machines Safely

TS228

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

–UN–23AUG88

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

DX,LOOSE –19–04JUN90–1/1

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Safety Information

Use Proper Tools

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

TS779

Use power tools only to loosen threaded parts and fasteners.

–UN–08NOV89

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.

Use only service parts meeting John Deere specifications.

DX,REPAIR –19–17FEB99–1/1

Service Tires Safely Explosive separation of a tire and rim parts can cause serious injury or death.

Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion.

Welding can structurally weaken or deform the wheel.

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

–UN–23AUG88

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.

TS211

210 05 10

DX,RIM –19–24AUG90–1/1

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Safety Information 210 05 11

L124515

When servicing front-wheel drive tractor with the rear wheels supported off the ground and rotating wheels by engine power, always support front wheels in a similar manner. Loss of electrical power or transmission/ hydraulic system pressure will engage the front driving wheels, pulling the rear wheels off the support if front wheels are not raised. Under these conditions, front drive wheels can engage even with switch in disengaged position.

–UN–06AUG94

Service Front-Wheel Drive Tractor Safely

LX,MFWD2 –19–01MAY91–1/1

Safety Information - Air Brake System CAUTION: Compressed air tank is pressurized!

LX008009

–UN–24APR96

Always relieve pressure before working on the air brake system. Do not carry out any welding jobs on the air brake system.

LX,AIRBRAKES –19–03MAR94–1/1

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Safety Information

TS266

Radar ground speed sensor emits a very low intensity microwave signal. It will not cause any ill effects during normal use. Although intensity is low, DO NOT look directly into face of sensor while in operation, to avoid any possible eye damage.

–UN–23AUG88

Avoid Eye Contact With Radar

RX,SAFTY,RADAR1 –19–21SEP92–1/1

Keep ROPS Installed Properly

TS212

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. A damaged ROPS should be replaced, not reused.

–UN–23AUG88

Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is loosened or removed for any reason. Tighten mounting bolts to proper torque.

DX,ROPS3 –19–03MAR93–1/1

Replace Safety Signs

–UN–23AUG88

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

TS201

210 05 12

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Safety Information 210 05 13

Dispose of Waste Properly

Do not pour waste onto the ground, down a drain, or into any water source.

TS1133

Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

–UN–26NOV90

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries.

Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

DX,DRAIN –19–03MAR93–1/1

Live With Safety

TS231

–19–07OCT88

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

DX,LIVE –19–25SEP92–1/1

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Safety Information 210 05 14

Safety Measures on Electronic Control Units CAUTION: Before installing test equipment on tractor, always shut off the engine and turn the key switch “OFF”.

IMPORTANT: Do not use a test lamp on any control unit. Only use a multimeter (JT05791A).

IMPORTANT: To protect electronic circuits, disconnect the battery and alternator before performing any welding on the tractor.

CAUTION: Always engage the park lock when performing tests with the engine running.

CAUTION: When testing is performed with the engine running, there is a risk of injury from rotating parts.

LX25599,0000243 –19–01JAN01–1/1

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Section 211

DIAGNOSTIC TROUBLE CODES Contents

211

Page

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Group ATC—ATC Diagnostic Trouble Codes ATC 000170.03 — Sending Unit for Inside Air Temperature, Shorted or Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-1 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-1 ATC 000170.04 — Sending Unit for Inside Air Temperature, Short to Ground . . . . . . 211-ATC-3 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-4 ATC 000171.03 — Sending Units for Ambient Air Temperature, Shorted or Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-6 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-7 ATC 000171.04 — Sending Units for Ambient Temperature, Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-11 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-11 ATC 000628.12 — Controller, Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-15 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-15 ATC 000630.02 — Controller, Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-16 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-16 ATC 000639.14 — 29-bit CAN BUS, High Error Rate . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-17 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-17 ATC 000871.03 — Refrigerant Pressure Sending Unit, Shorted Circuit. . . . . . . . . 211-ATC-18 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-18 ATC 000871.04 — Refrigerant Pressure Sending Unit, Grounded or Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-20 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-21 ATC 000876.03 — Air-Conditioning Relay, Shorted or Open Circuit . . . . . . . . . . . . . 211-ATC-23 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-24 ATC 000876.04 — Air-Conditioning Relay, Grounded Circuit . . . . . . . . . . . . . . . . . . 211-ATC-27 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-27 ATC 000876.10 — Compressor Clutch Engages and Disengages Too Often . . . 211-ATC-30 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-30 ATC 000876.14 — Compressor Switches Off Due to Engine Overheating . . . . . . . 211-ATC-35 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-35 ATC 000919.03 — Solar Sensor Activated . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-36

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-36 ATC 000923.03 — Driver Unit for the Fan Motors, Shorted Circuit . . . . . . . . . . . . . 211-ATC-37 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-37 ATC 000923.04 — Fan Motor Driver Unit, Grounded or Open Circuit . . . . . . . . . . . 211-ATC-40 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-40 ATC 000923.12 — Fan Motors, Malfunction . . . . . . . . . . . . . . . . . . . . . . 211-ATC-42 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-42 ATC 001079.03 — 5-volt Power Supply, Shorted or Open Circuit . . . . . . . . . . . . . 211-ATC-45 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-45 ATC 001079.04 — 5-volt Power Supply, Grounded Circuit . . . . . . . . . . . . . . . . . . 211-ATC-47 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-47 ATC 001546.03 — Potentiometer for Position of Water Valve, Shorted or Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-49 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-50 ATC 001546.04 — Potentiometer for Water Valve Position, Grounded Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-52 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-53 ATC 001547.03 — Sending Units for Evaporator Core Temperature, Shorted or Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-55 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-56 ATC 001547.04 — Sending Unit for Evaporator Core Temperature, Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-58 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-58 ATC 001548.03 — Sending Unit for Actual Outlet Air Temperature, Shorted or Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-60 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-61 ATC 001548.04 — Sending Unit for Actual Outlet Air Temperature, Grounded Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-63 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-63 ATC 001549.03 — Water Valve Motor, Shorted Circuit. . . . . . . . . . . . . . . . . . . . 211-ATC-65 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-66

TM4726 (01NOV03)

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Contents

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ATC 001549.04 — Water Valve Motor, Grounded Circuit . . . . . . . . . . . . . . . . . . 211-ATC-68 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-69 ATC 001549.07 — Water Valve, Malfunction . . . . . . . . . . . . . . . . . . . . . . 211-ATC-71 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-72 ATC 001549.13 — Water Valve Not Calibrated . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-74 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-75 ATC 001552.03 — Temperature Control, Shorted or Open Circuit . . . . . . . . . . . . . 211-ATC-76 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-76 ATC 001552.04 — Temperature Control, Grounded Circuit . . . . . . . . . . . . . . . . . . 211-ATC-77 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-78 ATC 001553.03 — Fan Speed Control, Shorted or Open Circuit . . . . . . . . . . . . . 211-ATC-79 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-79 ATC 001553.04 — Fan Speed Control, Grounded Circuit . . . . . . . . . . . . . . . . . . 211-ATC-80 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-80 ATC 002000.09 — Engine Control Unit is not Transmitting any Data (Coolant Temperature) . . . . . . . . . . . . . . . . . . . . . 211-ATC-81 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-82 ATC 523848.03 — Potentiometer for Position of Air Distribution Flaps, Shorted or Open Circuit . . . . . . . . . . . . . 211-ATC-84 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-84 ATC 523848.04 — Potentiometer for Position of Air Distribution Flaps, Grounded Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-87 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-87 ATC 523848.05 — Adjusting Motor for Air Distribution, Shorted Circuit . . . . . . . . . . 211-ATC-89 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-90 ATC 523848.06 — Adjusting Motor for Air Distribution, Grounded Circuit . . . . . . . . 211-ATC-92 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-92 ATC 523848.07 — Air Distribution, Malfunction . . . . . . . . . . . . . . . . . . . . . . 211-ATC-94 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-95 ATC 523848.13 — Adjusting Motor for Air Distribution, Not Calibrated . . . . . . . . . . 211-ATC-97 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-97 ATC 523860.03 — Defog Sensor, Shorted or Open Circuit . . . . . . . . . . . . . . . . . . . . . 211-ATC-98 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-99 ATC 523860.04 — Defog Sensor, Grounded Circuit . . . . . . . . . . . . . . . . . 211-ATC-101 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-101

ATC 523860.02 — Defog Sensor, Frequency out of Valid Range . . . . . . . 211-ATC-103 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . 211-ATC-103

TM4726 (01NOV03)

Group BCU—BCU Diagnostic Trouble Codes BCU 000070.31 — Handbrake Failure . . . . 211-BCU-1 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-1 BCU 000084.02 — Wheel Speed Sender, Circuit Fault . . . . . . . . . . . . . . . . . . . . . . 211-BCU-2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-2 BCU 000168.16 — System Voltage Too High (Engine Running). . . . . . . . . . . . . . . . . . . 211-BCU-4 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-4 BCU 000168.17 — System Voltage Too Low (Engine Speed Over 1500 rpm) . . . . 211-BCU-5 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-5 BCU 000168.18 — System Voltage Too Low (Engine Speed Up to 1500 rpm). . . . 211-BCU-6 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-7 BCU 000186.02 — Rear PTO Speed Sender, Circuit Fault . . . . . . . . . . . . . . . . . . . . . . 211-BCU-8 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-8 BCU 000186.17 — Rear PTO Speed Not Registered . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-9 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-10 BCU 000190.02 — Engine Speed Sender, Circuit Fault . . . . . . . . . . . . . . . . . . . . . 211-BCU-11 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-12 BCU 000629.12 — Control Unit, Internal Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-13 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-13 BCU 000639.12 — Control Unit, Internal Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-13 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-13 BCU 000639.13 — 29-bit CAN BUS, High Error Rate . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-14 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-14 BCU 000639.19 — 29-bit CAN BUS, Very High Error Rate . . . . . . . . . . . . . . . . . . . 211-BCU-15 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-16 BCU 000746.31 — Differential Lock Solenoid Valve, Circuit Fault . . . . . . . . . 211-BCU-17 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-17 BCU 000980.07 — Rear PTO, Switch Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-18 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-19 BCU 001676.31 — Relay for LTC Coolant Pump, Circuit Fault . . . . . . . . . . . . . . . . 211-BCU-20 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 211-BCU-20 BCU 001882.02 — Front PTO Speed Sender, Circuit Fault . . . . . . . . . . . . . . . 211-BCU-21

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