370E, 410E, and 460E Articulated Dump Truck Diagnostic
OPERATION AND TEST MANUAL iT4/S3B models 370E, 410E, 460E (SN. E634583-668586) TM12406 27 DEC 15 (ENGLISH)
For complete service information also see: 370E, 410E and 460E Articulated Dump Truck Repair
TM12408
JDLink (MTG) Technical Manual
TM114519
120 Series Hydraulic Cylinders
CTM120519
TMV 1500 Series Axle 370E, 410E, 460E Series Outboard Planetary Axles
CTM115319
6135 PowerTech Diesel Engine (Interim Tier 4) Level 22 ECU
CTM104919
John Deere Construction and Forestry Pinted by Belgreen
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Table of contents FOREWORD MANUAL IDENTIFICATION—READ THIS FIRST! Section 9000 - GENERAL INFORMATION Group 01 - Safety Section 9001 - DIAGNOSTICS Group 10 - Transmission Control Unit (TCU) Diagnostic Trouble Codes Group 20 - Engine Control Unit (ECU) Diagnostic Trouble Codes Group 30 - Chassis Control Unit (CCU) Diagnostic Trouble Codes Group 40 - CAN Monitor Unit (CMU) Diagnostic Trouble Codes Group 50 - 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes Group 60 - 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Group 10 - Operational Checkout Procedure Section 9010 - ENGINE Group 05 - Theory of Operation Group 15 - Diagnostic Information Group 20 - Adjustments Group 25 - Tests Section 9015 - ELECTRICAL SYSTEM Group 05 - System Information Group 10 - System Diagrams Group 15 - Sub-System Diagnostics Group 16 - Monitor Operation Group 20 - References Section 9020 - POWER TRAIN Group 05 - Theory of Operation Group 15 - Diagnostic Information Group 25 - Tests Section 9025 - HYDRAULIC SYSTEM Group 05 - Theory of Operation Group 15 - Diagnostic Information Group 25 - Test Section 9031 - HEATING AND AIR CONDITIONING Group 05 - Theory of Operation Group 15 - Diagnostic Information Group 25 - Tests
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TM12406-OPERATION AND TEST MANUAL
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TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
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.
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TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Manual Identification—READ THIS FIRST! IMPORTANT: Use only supporting manuals designated for your specific machine. If incorrect manual is chosen, improper service may occur. Verify product identification number (PIN) when choosing the correct manual. Choosing the Correct Supporting Manuals John Deere articulated dump trucks are available in different machine configurations based on the various markets into which they are sold. Different supporting manuals exist for different machine configurations. When necessary, product identification numbers are listed on the front covers of articulated dump truck manuals. These numbers are used to identify the correct supporting manual for your machine. Product Identification Number
PIN Plate Location
PIN Plate LEGEND: 1 PIN Plate 2 17 Character PIN The product identification number (PIN) plate (1) is located on the left-side of equipment frame under operator′s station. Each machine has a 17 character PIN (2) shown on PIN plate.
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TM12406-OPERATION AND TEST MANUAL
GENERAL INFORMATION
(g) by Belgreen v2.0
PIN Identification PIN Identification 3
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3—World Code —Identifies location where machine is manufactured. 4—Machine Model Identifier —Identifies model number. 5—Option Code —Identifies which major machine option is equipped. This digit will change from one machine to another. 6—Check Letter —This is a random character assigned by the factory. This is not used in machine identification. 7—Manufacturing Year Code —Identifies year of machine manufacture. 8—Engine Emission Code —Represents engine emission certification. 9—Machine Serial Number The PIN identifies the producing factory, machine model number, machine option, year of manufacture, engine emission level, and machine serial number. The following is an example for a 370E Interim Tier 4/Stage IIIB machine:
PIN Identification 1DW370EX_ _E123456 1DW ..........
World Code (manufacturing location) 1DW ..........
Davenport Works
1T0 ..........
Dubuque Works
370E ..........
Machine Model Identifier
X ..........
Machine Option Code X ..........
Base Machine
T ..........
Truck
_ ..........
Check Letter (variable)
_ ..........
Manufacturing Year Code (variable) C ..........
2012
D ..........
2013
E ..........
2014
F ..........
2015
G ..........
2016
E ..........
Engine Emission Code C ..........
Tier 2/Stage II
D ..........
Tier 3/Stage IIIA
E ..........
Interim Tier 4/Stage IIIB
F ..........
Tier 4
123456 ..........
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Machine Serial Number
Section 9000 page 2
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Section 9000 - GENERAL INFORMATION Table of contents Group 01 - Safety ..................................................................................................................................... 1 Safety and Operator Convenience Features ......................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 2 Operate Only If Qualified ...................................................................................................................... 3 Wear Protective Equipment .................................................................................................................. 4 Avoid Unauthorized Machine Modifications .......................................................................................... 4 Inspect Machine ................................................................................................................................... 4 Stay Clear of Moving Parts ................................................................................................................... 5 Avoid High-Pressure Fluids ................................................................................................................... 5 Avoid High-Pressure Oils ...................................................................................................................... 6 Work In Ventilated Area ........................................................................................................................ 6 Prevent Fires ........................................................................................................................................ 7 Prevent Battery Explosions ................................................................................................................... 8 Handle Chemical Products Safely ......................................................................................................... 8 Decommissioning: Proper Recycling and Disposal of Fluids and Components ..................................... 8 Exhaust Filter Ash Handling and Disposal ............................................................................................ 9 Prepare for Emergencies ...................................................................................................................... 9 Clean Debris from Machine ................................................................................................................ 10 Use Steps and Handholds Correctly ................................................................................................... 10 Start Only From Operator′s Seat ......................................................................................................... 11 Use and Maintain Seat Belt ................................................................................................................ 11 Prevent Unintended Machine Movement ............................................................................................ 11 Avoid Work Site Hazards .................................................................................................................... 12 Keep Riders Off Machine .................................................................................................................... 13 Avoid Backover Accidents .................................................................................................................. 14 Avoid Machine Tip Over ...................................................................................................................... 14 Operating on Slopes ........................................................................................................................... 15 Operating or Traveling On Public Roads ............................................................................................. 15 Inspect and Maintain ROPS ................................................................................................................. 15 Add and Operate Attachments Safely ................................................................................................ 16 Park and Prepare for Service Safely ................................................................................................... 16 Service Cooling System Safely ........................................................................................................... 17 Remove Paint Before Welding or Heating ........................................................................................... 17 Make Welding Repairs Safely ............................................................................................................. 18 Drive Metal Pins Safely ....................................................................................................................... 18 Service Tires Safely ............................................................................................................................ 19 Clean Exhaust Filter Safely ................................................................................................................. 19
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TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
Group 01 - Safety Safety and Operator Convenience Features
Safety Features Please remember, the operator is the key to preventing accidents. 1. ROPS/FOPS Cab Protection. Structures designed to help protect the operator are certified to ISO, SAE, and OSHA. Enclosures also deflect sun and rain. 2. Cab with Heater/Defroster. Cab ventilation system circulates both outside and inside air through a filter for a clean working environment. Built-in defroster vents direct air flow for effective window defogging/deicing. 3. Dump Body Service Lock. A mechanical lock is provided for working on or around this machine with the dump body raised. 4. Stop/Backup Lights. Highly visible lights are standard equipment. 5. Backup Alarm. Alerts bystanders when reverse travel direction is selected by the operator. 6. Independent Parking Brake. Is mechanically engaged and hydraulically released. It engages whenever the engine stop switch is turned on or the park brake switch is activated. 7. Articulation Locking Bar. A self-storing mechanical lock is provided for transport or service. 8. Secondary Steering. Ground driven, continuously in operation. Secondary steering indicator light will light when active. 9. Horn. Standard horn is useful when driving or when signaling co-workers. 10. Halogen Lights and Turn Signals. High-intensity halogen drive/work lights and high-visibility turn signals are standard equipment. 11. Engine Fan Guard. A fan guard on both fan doors helps prevent contact with rotating fan blades. 12. Bypass Start Protection. Shielding over the starter terminals helps prevent dangerous bypass starting. 13. Transmission Retarder. Engages whenever the truck is in motion and the operator lets up on the accelerator. 14. Seat Belt Retractors. Help keep belts clean and convenient to use. 15. Mirrors. Large exterior mirrors on both sides offer the operator a view of activity behind the machine. 16. Large Windshield Wiper with Washer. Extra long wiper cleans large windshield area.
Recognize Safety Information
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Section 9000 page 1
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
Safety alert Symbols
Safety Alert Symbols This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the potential of personal injury. Follow the precautions and safe operating practices highlighted by this symbol. A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards. On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.
Follow Safety Instructions
Safety Messages Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Use this operator’s manual for correct safety sign placement. Be sure that new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer. There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator′s manual. Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction. <- Go to Section TOC
Section 9000 page 2
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
Keep your machine in proper working condition. Unauthorized modifications to the machine could impair the function or safety and affect machine life. If you do not understand any part of this manual and need assistance, contact your John Deere dealer.
Operate Only If Qualified Do not operate this machine unless the operator′s manual has been read carefully, and you have been qualified by supervised training and instruction. Operator should be familiar with the job site and surroundings before operating. Try all controls and machine functions with the machine in an open area before starting to work. Know and observe all safety rules that may apply to every work situation and work site.
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Section 9000 page 3
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
Wear Protective Equipment
Protective Clothing Guard against injury from flying pieces or metal or debris; wear goggles or safety glasses. Wear close fitting clothing and safety equipment appropriate to the job. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Radio or music headphones are not suitable to use for hearing protection.
Avoid Unauthorized Machine Modifications John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance. Non-John Deere parts, or any damage or malfunctions resulting from their use, are not covered by any John Deere warranty. Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance. Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance, or reliability.
Inspect Machine
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Section 9000 page 4
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
Inspect Machine Inspect machine carefully each day by walking around it before starting. Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.
Stay Clear of Moving Parts
Stay Clear of Moving Parts Entanglements in moving parts can cause serious injury. Stop engine before examining, adjusting, or maintaining any part of machine with moving parts. Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.
Avoid High-Pressure 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. <- Go to Section TOC
Section 9000 page 5
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
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 could result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.
Work In Ventilated Area
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Section 9000 page 6
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
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. <- Go to Section TOC
Section 9000 page 7
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
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
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Section 9000 page 8
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
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.
Exhaust Filter Ash Handling and Disposal CAUTION: Under federal, state, and local laws or regulations, exhaust filter ash can be classified as a hazardous waste. Hazardous waste must be disposed of in accordance with all applicable federal, state, and local laws or regulations governing hazardous waste disposal. Only a qualified service provider should remove ash from the exhaust filter. Personal protective equipment and clothing, maintained in a sanitary and reliable condition, should be used when handling and cleaning exhaust filter. See your authorized dealer for exhaust filter ash handling and disposal.
Prepare for Emergencies
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Section 9000 page 9
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
First Aid Kit Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
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 could 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 <- Go to Section TOC
Section 9000 page 10
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
Prevent falls by facing the machine when you get on and off. Maintain 3-point contact with steps and handrails. Never use machine controls as handholds. Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.
Start Only From Operator′s Seat
Operate Only From Operators Seat Avoid unexpected machine movement. Start engine only while sitting in operator′s seat. Ensure that all controls and working tools are in proper position for a parked machine. Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.
Use and Maintain Seat Belt
Use and Maintain Seat Belt Use seat belt when operating machine . Remember to fasten seat belt when loading and unloading from trucks and during other uses. Examine seat belt frequently. Be sure that webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly. The complete seat belt assembly should be replaced every three years, regardless of appearance.
Prevent Unintended Machine Movement
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Section 9000 page 11
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
25-Button Sealed Switch Module (SSM) Park Function LEGEND: 1 2 3
Engine Stop Switch Park Brake Switch Neutral Selection Switch
Be careful not to accidentally actuate controls when coworkers are present. Ensure dump body is lowered during work interruptions. Push neutral selection switch (3) to engage neutral gear, push park brake switch (2) to engage park brake, and push engine stop switch (1) to stop engine before allowing anyone to approach the machine. Follow these same precautions before standing up, leaving the operator’s seat, or exiting the machine.
Avoid Work Site Hazards
Contact with Overhead Wires
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Section 9000 page 12
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
Operate Only 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.
Keep Riders Off Machine
Keep Riders Off Machine Use seat belt at all times. Only allow operator on machine except when necessary for instruction or short periods of observation. Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. They also may obstruct operator’s view or impair his ability to operate machine safely. <- Go to Section TOC
Section 9000 page 13
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
Use the instructional seat only to accommodate trainers or persons needing to observe machine operation for short periods.
Avoid Backover Accidents
Avoid Backover Accidents Before moving machine, be sure that all persons are clear of machine path. Turn around and look directly for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair. Be certain reverse warning alarm is working properly. Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate. Do not rely on the rear camera and radar object detection systems to determine if personnel are behind the machine. The system has limitations due to maintenance practices, environmental conditions, and operating range.
Avoid Machine 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. Use extra care when bin (dump body) is raised. Machine stability is greatly reduced when bin (dump body) is raised. Drive slowly. Avoid sharp turns and uneven ground. <- Go to Section TOC
Section 9000 page 14
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
Be careful on slopes and soft, rocky, or frozen ground. Traction and stability are reduced by slopes and adverse terrain. Avoid piles of dirt and banks or excavations that may cave in and cause the machine to tip or fall. Do not overload the machine. Oversize loads reduce machine stability, increase tire flex, and erode travel surfaces. Braking capability and brake life are also reduced. If machine tips, carefully inspect brake and hydraulic lines, electrical wiring, and machine structure before operating.
Operating on Slopes
Operating on Slopes Avoid side slope travel whenever possible. Check service brake condition frequently when operating on slopes. Select low gear speed before starting down slope. The maximum slope you can operate on will be limited by ground conditions and the load being handled. Use the transmission retarder, exhaust brake, and service brakes to control speed. Sudden brake application with a loaded bin (dump body) could cause loss of machine control.
Operating or Traveling On Public Roads
Operating or Traveling On Public Roads Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lighting and markings to assure they are visible to other drivers. Install additional lights, beacon lights, slow moving vehicle (SMV) emblems, or other devices and use as required to make the machine visible and identify it as a work machine. Check state and local regulations to assure compliance. Keep these devices clean and in working condition.
Inspect and Maintain ROPS A damaged rollover protective structure (ROPS) should be replaced, not reused. The protection offered by ROPS could be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting. <- Go to Section TOC
Section 9000 page 15
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
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 could affect machine stability or reliability and could create a hazard for others near the machine. Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or recommended. Verify that all connections are secure and attachment responds properly to controls. Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion.
Park and Prepare for Service Safely
Do Not Operate Tag
Support Machine Properly Warn others of service work. Always park and prepare your machine for service or repair properly. Park machine on a level surface. Lower bin (dump body) unless raised position is required for service. Engage park brake. Stop engine. Lower struts completely. Attach a “Do Not Operate” tag in an obvious place in the operator′s station. Install the articulation lock bar. Install service locks if bin (dump body) or cab is raised for service. <- Go to Section TOC
Section 9000 page 16
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
Securely support machine before working under it. Install wheel chocks to ensure that machine cannot move backward or forward during service. Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.
Service Cooling System Safely
Cooling System Explosive release of fluids from pressurized cooling system can cause serious burns. Do not service radiator through the radiator cap. Only fill through the surge tank filler cap. Shut off engine. Only remove surge tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely.
Remove Paint Before Welding or Heating
Toxic Fumes Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Remove paint before heating: Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. Do not use a chlorinated solvent in areas where welding will take place. Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly. <- Go to Section TOC
Section 9000 page 17
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
Make Welding Repairs Safely
Heating Near Pressurized Fluid Lines IMPORTANT: Disable electrical power before welding. Turn off main battery switch and disconnect positive (+) and negative (-) battery cables. Do not weld or apply heat on any part of a reservoir or tank that has contained oil or fuel. Heat from welding and cutting can cause oil, fuel, or cleaning solution to create gases which are explosive, flammable, or toxic. Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines malfunction as a result of heating. Do not let heat go beyond work area to nearby pressurized lines. Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure there is good ventilation. Wear eye protection and protective equipment when welding.
Drive Metal Pins Safely
Hardened Metal Parts Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth could dislodge chips at high velocity. Use a soft hammer or a brass bar between hammer and object to prevent chipping.
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Section 9000 page 18
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
Service Tires Safely
Explosive Tire and Rim Parts Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
Clean Exhaust Filter Safely
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Section 9000 page 19
TM12406-OPERATION AND TEST MANUAL
Section 9000 - GENERAL INFORMATION
Group 01: Safety
Fire Safety
Hand Over Flame
Moving Parts
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Section 9000 page 20
TM12406-OPERATION AND TEST MANUAL
DIAGNOSTICS
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Stop During exhaust filter cleaning operations, the engine may run at elevated idle and hot temperatures for an extended period of time. Exhaust gases and exhaust filter components reach temperatures hot enough to burn people, or ignite or melt common materials. Keep machine away from people, animals, or structures which may be susceptible to harm or damage from hot exhaust gases or components. Avoid potential fire or explosion hazards from flammable materials and vapors near the exhaust. Keep exhaust outlet away from people and anything that can melt, burn, or explode. Closely monitor machine and surrounding area for smoldering debris during and after exhaust filter cleaning. Adding fuel while an engine is running can create a fire or explosion hazard. Always stop engine before refueling machine and clean up any spilled fuel. Always make sure that engine is stopped while hauling machine on a truck or trailer. Contact with exhaust components while still hot can result in serious personal injury. Avoid contact with these components until cooled to safe temperatures. If service procedure requires engine to be running: Only engage power-driven parts required by service procedure Ensure that other people are clear of operator station and machine Keep hands, feet, and clothing away from power-driven parts. Always disable movement (neutral), set the parking brake or mechanism and disconnect power to attachments or tools before leaving the operator’s station. Shut off engine and remove key (if equipped) before leaving the machine unattended.
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Section 9001 page 21
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Section 9001 - DIAGNOSTICS Table of contents Group 10 - Transmission Control Unit (TCU) Diagnostic Trouble Codes ......................................... 1 Battery Low Undervoltage Diagnostic Procedure ................................................................................. 1 Battery Overvoltage Diagnostic Procedure ........................................................................................... 2 Battery Undervoltage Diagnostic Procedure ......................................................................................... 4 Battery Undervoltage During Engine Start Diagnostic Procedure ......................................................... 6 EC-II Internal 5V Power Supply Overvoltage Diagnostic Procedure ...................................................... 8 EC-II Internal 5V Power Supply Undervoltage Diagnostic Procedure .................................................. 10 EC-II Internal 7V Power Supply Undervoltage Diagnostic Procedure .................................................. 11 Speed Sensor Supply Overvoltage Diagnostic Procedure ................................................................... 12 Speed Sensor Supply Undervoltage Diagnostic Procedure ................................................................. 14 Speed Sensor voltage Low Diagnostic Procedure ............................................................................... 15 Temp/Oil Filt Supply Overvoltage Diagnostic Procedure .................................................................... 17 Temp/Oil Filt Supply Undervoltage Diagnostic Procedure ................................................................... 19 Temp/Oil Filt Supply Voltage Low Diagnostic Procedure ..................................................................... 20 Supply 1 For Sensors Overvoltage Diagnostic Procedure ................................................................... 22 Supply 1 For Sensors Undervoltage Diagnostic Procedure ................................................................. 24 Supply 1 For Sensors Short to Ground Diagnostic Procedure ............................................................. 25 Propvalve Supply 1 Overvoltage Diagnostic Procedure ...................................................................... 27 Propvalve Supply 1 Undervoltage Diagnostic Procedure .................................................................... 28 VPS1 Power Supply Voltage Low Diagnostic Procedure ...................................................................... 29 Propvalve Supply 2 Overvoltage Diagnostic Procedure ...................................................................... 31 Propvalve Supply 2 Undervoltage Diagnostic Procedure .................................................................... 32 VPS2 Power Supply Voltage Low Diagnostic Procedure ...................................................................... 33 TCU Overtemp Diagnostic Procedure ................................................................................................. 34 TCU Temp Invalid Diagnostic Procedure ............................................................................................. 35 Internal Error 1 Diagnostic Procedure ................................................................................................. 35 Internal Error 2 Diagnostic Procedure ................................................................................................. 36 Internal Error 3 Diagnostic Procedure ................................................................................................. 36 Internal Error 4 Diagnostic Procedure ................................................................................................. 37 Unknown Transmission Control Unit (TCU) Hardware Detected Diagnostic Procedure ....................... 38 Turbine Speed Unknown Input Diagnostic Procedure ......................................................................... 39 Turbine Speed Sensor Input Overvoltage Diagnostic Procedure ........................................................ 41 Turbine Speed Sensor Voltage Low Diagnostic Procedure .................................................................. 43 Turbine Speed Input Speed Mismatch Diagnostic Procedure ............................................................. 45 Turbine Speed Error ROT DIR Unknown Diagnostic Procedure ........................................................... 47 Turbine Speed Error Speed Unknown Diagnostic Procedure .............................................................. 49 Turbine Speed Error ROT DIR Mismatch Diagnostic Procedure ........................................................... 51 Speed Sensor 1 Unknown Input Diagnostic Procedure ....................................................................... 53 Speed Sensor 1 Overvoltage Diagnostic Procedure ............................................................................ 55 Speed Sensor 1 Voltage Low Diagnostic Procedure ............................................................................ 57 Speed Sensor 1 Speed Mismatch Diagnostic Procedure ..................................................................... 59 Speed Sensor 1 DIR ROT Unknown Diagnostic Procedure .................................................................. 61 Speed Sensor 1 Speed Unknown Diagnostic Procedure ..................................................................... 63 Speed Sensor 1 DIR ROT Mismatch Diagnostic Procedure .................................................................. 65 Speed Sensor 2 Unknown Input Diagnostic Procedure ....................................................................... 67 Speed Sensor 2 Overvoltage Diagnostic Procedure ............................................................................ 69 Speed Sensor 2 Voltage Low Diagnostic Procedure ............................................................................ 71 Speed Sensor 2 Speed Mismatch Diagnostic Procedure ..................................................................... 73 Speed Sensor 2 DIR ROT Unknown Diagnostic Procedure .................................................................. 75 Speed Sensor 2 Speed Unknown Diagnostic Procedure ..................................................................... 77 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
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Speed Sensor 2 DIR ROT Mismatch Diagnostic Procedure .................................................................. 79 Output Speed Sensor Unknown Input Diagnostic Procedure .............................................................. 81 Output Speed Sensor Overvoltage Diagnostic Procedure ................................................................... 83 Output Speed Sensor Voltage Low Diagnostic Procedure ................................................................... 85 Output Speed Sensor Speed Mismatch Diagnostic Procedure ............................................................ 87 Output Speed Sensor DIR ROT Unknown Diagnostic Procedure ......................................................... 89 Output Speed Sensor Speed Unknown Diagnostic Procedure ............................................................ 91 Output Speed Sensor DIR ROT Mismatch Diagnostic Procedure ......................................................... 93 Unknown Electrical Component at Speed Sensor Input 5 Diagnostic Procedure ................................ 95 Speed Sensor Input 5 Overvoltage Diagnostic Procedure .................................................................. 97 Speed Sensor Input 5 Open or Short to Ground Diagnostic Procedure ............................................... 99 Unknown Electrical Component at Voltage Input 1 Diagnostic Procedure ........................................ 101 Unknown Electrical Component at Voltage Input 2 Diagnostic Procedure ........................................ 103 Sump Temp Input Unknown Input Diagnostic Procedure .................................................................. 105 Sump Temp Sensor Voltage High Diagnostic Procedure .................................................................. 107 Sump Temp Sensor Overvoltage Diagnostic Procedure ................................................................... 109 Sump Temp Sensor Voltage Low Diagnostic Procedure ................................................................... 111 Torq/RTDR Temp Snsr Unknown Input Diagnostic Procedure ........................................................... 113 Torq/RTDR Temp Snsr Unknown Voltage High Diagnostic Procedure ............................................... 115 Torq/RTDR Temp Snsr Overvoltage Diagnostic Procedure ............................................................... 117 Torq/RTDR Temp Snsr Ground Low Diagnostic Procedure ................................................................ 118 Unknown Electrical Component at Current Input 1 Diagnostic Procedure ........................................ 120 Unknown Electrical Component at Current Input 2 Diagnostic Procedure ........................................ 122 Oil Filt Rest Switch Overvoltage Diagnostic Procedure ..................................................................... 124 Oil Filt Rest Switch Undervoltage Diagnostic Procedure ................................................................... 126 Oil Filt Rest Switch Voltage Low Diagnostic Procedure ..................................................................... 128 Clutch A Slip Unintentional Slip Diagnostic Procedure ...................................................................... 130 Current Output 1 Unknown ELC Comp Diagnostic Procedure ........................................................... 132 Clutch A Propvalve Voltage High Diagnostic Procedure ................................................................... 134 Clutch A Propvalve Current Low Diagnostic Procedure ..................................................................... 136 Clutch A Propvalve Ground Low Diagnostic Procedure ..................................................................... 138 Clutch A Propvalve Short to ALT Valve Diagnostic Procedure ........................................................... 140 Clutch B Slip Unintentional Slip Diagnostic Procedure ...................................................................... 142 Current Output 2 Unknown ELC Comp Diagnostic Procedure ........................................................... 144 Clutch B Propvalve Voltage High Diagnostic Procedure ................................................................... 146 Clutch B Propvalve Current Low Diagnostic Procedure ..................................................................... 148 Clutch B Propvalve Ground Low Diagnostic Procedure ..................................................................... 150 Clutch B Propvalve Short to ALT Valve Diagnostic Procedure ........................................................... 152 Clutch C Slip Unintentional Slip Diagnostic Procedure ...................................................................... 154 Current Output 3 Unknown ELC Comp Diagnostic Procedure ........................................................... 156 Clutch C Propvalve Voltage High Diagnostic Procedure ................................................................... 158 Clutch C Propvalve Current Low Diagnostic Procedure ..................................................................... 160 Clutch C Propvalve Ground Low Diagnostic Procedure ..................................................................... 162 Clutch C Propvalve Short to ALT Valve Diagnostic Procedure ........................................................... 164 Clutch D Slip Unintentional Slip Diagnostic Procedure ..................................................................... 166 Current Output 4 Unknown ELC Comp Diagnostic Procedure ........................................................... 168 Clutch D Propvalve Voltage High Diagnostic Procedure ................................................................... 170 Clutch D Propvalve Current Low Diagnostic Procedure .................................................................... 172 Clutch D Propvalve Ground Low Diagnostic Procedure ..................................................................... 174 Clutch D Propvalve Short to ALT Valve Diagnostic Procedure .......................................................... 176 Clutch R Slip Unintentional Slip Diagnostic Procedure ...................................................................... 178 Current Output 5 Unknown ELC Comp Diagnostic Procedure ........................................................... 180 Clutch R Propvalve Voltage High Diagnostic Procedure ................................................................... 182 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
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Clutch R Propvalve Current Low Diagnostic Procedure ..................................................................... 184 Clutch R Propvalve Ground Low Diagnostic Procedure ..................................................................... 186 Clutch R Propvalve Short to ALT Valve Diagnostic Procedure ........................................................... 188 Clutch F Slip Unintentional Slip Diagnostic Procedure ...................................................................... 190 Current Output 6 Unknown ELC Comp Diagnostic Procedure ........................................................... 192 Clutch F Propvalve Voltage High Diagnostic Procedure .................................................................... 194 Cutch F Propvalve Current Low Diagnostic Procedure ...................................................................... 196 Clutch F Propvalve Voltage Low Diagnostic Procedure ..................................................................... 198 Clutch F Propvalve Short to ALT Valve Diagnostic Procedure ........................................................... 200 Clutch V Slip Unintentional Slip Diagnostic Procedure ...................................................................... 202 Current Output 7 Unknown ELC Comp Diagnostic Procedure ........................................................... 204 Clutch V Propvalve Voltage High Diagnostic Procedure ................................................................... 206 Clutch V Propvalve Current Low Diagnostic Procedure ..................................................................... 208 Clutch V Propvalve Ground Low Diagnostic Procedure ..................................................................... 210 Clutch V Propvalve Short to ALT Valve Diagnostic Procedure ........................................................... 212 Clutch E Slip Unintentional Slip Diagnostic Procedure ...................................................................... 214 Current Output 8 Unknown ELC Comp Diagnostic Procedure ........................................................... 216 Clutch E Propvalve Voltage High Diagnostic Procedure .................................................................... 218 Cutch E Propvalve Current Low Diagnostic Procedure ...................................................................... 220 Clutch E Propvalve Voltage Low Diagnostic Procedure ..................................................................... 222 Clutch E Propvalve Short to ALT Valve Diagnostic Procedure ........................................................... 224 TORQ CVTR Slip Unintentional Slip Diagnostic Procedure ................................................................ 226 Current Output 9 Unknown ELC Comp Diagnostic Procedure ........................................................... 228 TORQ CVTR Propvalve Voltage High Diagnostic Procedure .............................................................. 230 TORQ CVTR Propvalve Current Low Diagnostic Procedure ............................................................... 232 TORQ CVTR Propvalve Voltage Low Diagnostic Procedure ............................................................... 234 TORQ CVTR Propvalve Short to ALT Valve Diagnostic Procedure ..................................................... 236 Current Output 10 Unknown ELC COMP Diagnostic Procedure ......................................................... 238 Retarder Propvalve Voltage High Diagnostic Procedure ................................................................... 240 Retarder Propvalve Current Low Diagnostic Procedure .................................................................... 242 Retarder Propvalve Voltage Low Diagnostic Procedure .................................................................... 244 Retarder Propvalve Short to ALT Valve Diagnostic Procedure .......................................................... 246 Current Output 11 Unknown ELC Comp Diagnostic Procedure ......................................................... 248 DIF Lock Propvalve Voltage High Diagnostic Procedure ................................................................... 250 DIF Lock Propvalve Current Low Diagnostic Procedure .................................................................... 252 DIF Lock Propvalve Voltage Low Diagnostic Procedure .................................................................... 254 DIF Lock Propvalve Short to ALT Valve Diagnostic Procedure .......................................................... 256 Trans Sump Oil Over Temperature Diagnostic Procedure ................................................................ 258 Trans Sump Oil Over Temperature Diagnostic Procedure ................................................................ 260 Retarder Oil Over Temperature Diagnostic Procedure ..................................................................... 262 Retarder Oil Moderately Severe Over Temperature Diagnostic Procedure ....................................... 264 Torque Converter Oil Over Temperature Diagnostic Procedure ....................................................... 266 Torque Converter Oil Moderately Severe Over Temperature Diagnostic Procedure ......................... 268 Filter Switch Signal Out of Range Diagnostic Procedure ................................................................... 270 Oil Filter Contaminated Diagnostic Procedure .................................................................................. 272 Trans Input Torque Too High Diagnostic Procedure .......................................................................... 273 Trans Output Overspeed Diagnostic Procedure ................................................................................ 274 Trans Calibration Data Lost Diagnostic Procedure ............................................................................ 276 Vehicle CAN Failure Diagnostic Procedure ........................................................................................ 278 Service CAN Failure Diagnostic Procedure ....................................................................................... 279 ECU Connection Loss Diagnostic Procedure ..................................................................................... 280 VCU Connection Loss Diagnostic Procedure ..................................................................................... 282 Park Brake Controller Connection Loss Diagnostic Procedure .......................................................... 284 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
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TC1 MSG Failure Invalid or Time-out Diagnostic Procedure .............................................................. 286 EEC1 MSG Failure Invalid or Time-out Diagnostic Procedure ............................................................ 287 EEC2 MSG Failure Invalid or Time-out Diagnostic Procedure ............................................................ 288 EEC3 MSG Failure Invalid or Time-out Diagnostic Procedure ............................................................ 289 EC1 MSG Failure Invalid or Time-out Diagnostic Procedure .............................................................. 290 B MSG Failure Invalid or Time-out Diagnostic Procedure .................................................................. 291 EBC1 MSG Failure Invalid or Time-out Diagnostic Procedure ............................................................ 292 CCVS MSG Failure Invalid or Time-out Diagnostic Procedure ........................................................... 293 V1 MSG Failure Invalid or Time-out Diagnostic Procedure ................................................................ 294 TSC1R MSG Failure Invalid or Time-out Diagnostic Procedure .......................................................... 295 JBERC1 MSG Failure Invalid or Time-out Diagnostic Procedure ........................................................ 296 JBRC MSG Failure Invalid or Time-out Diagnostic Procedure ............................................................ 297 Operation MODE CMD Invalid Command Diagnostic Procedure ....................................................... 297 Transmission CMD Invalid Command Diagnostic Procedure ............................................................. 298 DIFF Lock CMD Invalid Command Diagnostic Procedure .................................................................. 299 Torq Converter CMD Invalid Command Diagnostic Procedure .......................................................... 299 Retarder CMD Invalid Command Diagnostic Procedure .................................................................... 300 Machine Configuration Invalid Command Diagnostic Procedure ...................................................... 300 Testmode Not Active Diagnostic Procedure ...................................................................................... 301 Overspeed Engine Diagnostic Procedure .......................................................................................... 302 Engine Speed Limitation Not Effective Diagnostic Procedure ........................................................... 303 Engine Speed Demand is Not Effective Diagnostic Procedure .......................................................... 304 Engine Torque Limitation Not Effective Diagnostic Procedure .......................................................... 305 Engine Torque Demand is Not Effective Diagnostic Procedure ......................................................... 306 Neutral Shift For Engine Protection Diagnostic Procedure ................................................................ 307 Engine Brake Demand is Not Effective Diagnostic Procedure .......................................................... 309 Safety Function Error Diagnostic Procedure ..................................................................................... 310 Transmission Protection—Unwanted Movement Diagnostic Procedure ............................................ 310 Transmission Protection—Movement in Wrong Direction Diagnostic Procedure .............................. 311 Transmission Protection—Limited Acceleration Blocked Diagnostic Procedure ................................ 312 Transmission Protection—Limited Acceleration Downshift Diagnostic Procedure ............................ 312 Transmission Protection—Wrong Reverse Output Diagnostic Procedure .......................................... 313 Transmission Protection—Unwanted Direction Change Diagnostic Procedure ................................. 314 Transmission Protection—Limits Torque Diagnostic Procedure ........................................................ 314 Transmission Protection—Limited Delay for Engaging in Gear Diagnostic Procedure ...................... 315 Safety Related Error In Transmission Diagnostic Procedure ............................................................. 316 Safety ERR In Vehicle Comm Diagnostic Procedure ......................................................................... 316 Safety Error Reaction Failed Diagnostic Procedure .......................................................................... 317 Neutral W/Vehicle Movement Diagnostic Procedure ......................................................................... 318 Group 20 - Engine Control Unit (ECU) Diagnostic Trouble Codes ................................................ 320 Throttle Input Sensor Voltage High Diagnostic Procedure ................................................................ 320 Throttle Input Sensor Voltage Low Diagnostic Procedure ................................................................. 322 Coolant Level Very Low Diagnostic Procedure .................................................................................. 324 Coolant Level Mechanical Fault Diagnostic Procedure ...................................................................... 327 Coolant Level Slightly Low Diagnostic Procedure ............................................................................. 329 Engine Coolant Level Moderately Low Diagnostic Procedure ........................................................... 331 000157.16 - Fuel Rail Pressure Very High ........................................................................................ 334 000157.17 - Fuel Rail Pressure Low when Starting ........................................................................... 335 Battery Voltage High Diagnostic Procedure ...................................................................................... 335 Battery Voltage Low Diagnostic Procedure ....................................................................................... 336 Engine Overspeed Moderately High Diagnostic Procedure ............................................................... 337 Starter Relay Voltage High Diagnostic Procedure ............................................................................. 338 Starter Relay Voltage Low Diagnostic Procedure .............................................................................. 340 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
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Starter Relay Current Low Diagnostic Procedure .............................................................................. 341 Starter Relay Current High Diagnostic Procedure ............................................................................. 343 Starter Relay Start Time Moderately High Diagnostic Procedure ..................................................... 344 CCU CAN Communication Error Diagnostic Procedure ...................................................................... 345 No Alternator Condition Exists Diagnostic Procedure ....................................................................... 347 Ether Start Aid Solenoid Current High Diagnostic Procedure ............................................................ 349 DPF Soot Load Above Normal Operating Level Diagnostic Procedure .............................................. 350 Group 30 - Chassis Control Unit (CCU) Diagnostic Trouble Codes ............................................... 351 Fuel Level Sensor Voltage High Diagnostic Procedure ..................................................................... 351 Fuel Level Sensor Voltage Low Diagnostic Procedure ...................................................................... 353 Brake Pressure Very Low Diagnostic Procedure ............................................................................... 355 Model Unknown Diagnostic Procedure ............................................................................................. 356 Tire Pressure Very Low Diagnostic Procedure .................................................................................. 357 Tire Pressure Moderately High Diagnostic Procedure ....................................................................... 359 Tire Pressure Moderately Low Diagnostic Procedure ........................................................................ 361 Tire Temperature Moderately High Diagnostic Procedure ................................................................ 363 Invalid App Config Diagnostic Procedure .......................................................................................... 364 Park Brake Actuator Voltage High Diagnostic Procedure .................................................................. 365 Park Brake Actuator Current Low Diagnostic Procedure ................................................................... 367 Park Brake Actuator Current High Diagnostic Procedure .................................................................. 369 Controller Not Programmed Diagnostic Procedure ........................................................................... 370 Controller Fault Diagnostic Procedure .............................................................................................. 370 CAN Lost Message Diagnostic Procedure ......................................................................................... 371 CAN BUS Off Diagnostic Procedure ................................................................................................... 372 Stop Lamp Circuit Voltage High Diagnostic Procedure ..................................................................... 373 Stop Lamp Circuit Voltage Low Diagnostic Procedure ...................................................................... 375 Stop Lamp Circuit Current Low Diagnostic Procedure ...................................................................... 377 Tire Sensor Fault Diagnostic Procedure ............................................................................................ 377 Brake Light Switch Voltage Low Diagnostic Procedure ..................................................................... 379 Fan Solenoid Voltage High Diagnostic Procedure ............................................................................. 380 Fan Solenoid Current Low Diagnostic Procedure .............................................................................. 382 Fan Solenoid Current High Diagnostic Procedure ............................................................................. 383 Fan Solenoid Current Moderately High Diagnostic Procedure .......................................................... 385 Fan Solenoid Voltage Slightly Low Diagnostic Procedure ................................................................. 387 Fan Solenoid Voltage Moderately Low Diagnostic Procedure ........................................................... 388 Articulation Sensor Voltage High Diagnostic Procedure ................................................................... 389 Articulation Sensor Voltage Low Diagnostic Procedure .................................................................... 391 EBS Voltage Low Diagnostic Procedure ............................................................................................ 393 EBS Brake Switch Bad Device Diagnostic Procedure ........................................................................ 395 CAN 2 Lost Message Diagnostic Procedure ...................................................................................... 396 CAN BUS Off Diagnostic Procedure ................................................................................................... 396 Air Conditioning Thermal Switch Voltage Low Diagnostic Procedure ................................................ 397 Air Conditioning Clutch Voltage High Diagnostic Procedure ............................................................. 398 Air Conditioning Clutch Current Low Diagnostic Procedure .............................................................. 399 Air Conditioning Clutch Current High Diagnostic Procedure ............................................................. 401 Hydraulic Temperature Very High Diagnostic Procedure .................................................................. 403 Hydraulic Oil Temperature Sensor Voltage High Diagnostic Procedure ............................................ 404 Hydraulic Oil Temperature Sensor Voltage Low Diagnostic Procedure ............................................. 406 Fan Speed High Diagnostic Procedure .............................................................................................. 407 Fan Speed Low Diagnostic Procedure ............................................................................................... 407 Fan Speed Sensor Bad Freq Data Diagnostic Procedure .................................................................. 409 Tire Sensor Batteries Low Diagnostic Procedure .............................................................................. 410 Hydraulic Oil Filter Pressure Very Low Diagnostic Procedure ........................................................... 411 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Hydraulic Oil Filter Voltage High Diagnostic Procedure .................................................................... 413 Hydraulic Oil Filter Stuck Open Diagnostic Procedure ...................................................................... 413 ECU CAN Comm Bad Update Rate Diagnostic Procedure ................................................................. 415 TCU CAN Comm Bad Update Rate Diagnostic Procedure ................................................................. 417 CMU CAN Comm Bad Update Rate Diagnostic Procedure ................................................................. 419 TPM CAN Comm Bad Update Rate Diagnostic Procedure ................................................................. 421 OBW CAN Comm Bad Update Rate Diagnostic Procedure ................................................................ 423 OC3 CAN Comm Bad Update Rate Diagnostic Procedure ................................................................. 424 OC4 CAN Comm Bad Update Rate Diagnostic Procedure ................................................................. 426 JDL CAN Comm Bad Update Rate Diagnostic Procedure ................................................................... 428 Hi Beam Headlight Switch Voltage Low Diagnostic Procedure ......................................................... 430 Hi Beam Headlight Voltage High Diagnostic Procedure .................................................................... 431 Hi Beam Headlight Current Low Diagnostic Procedure ..................................................................... 432 Hi Beam Headlight Current High Diagnostic Procedure .................................................................... 433 Lo Beam Headlight Voltage High Diagnostic Procedure ................................................................... 435 Lo Beam Headlight Current Low Diagnostic Procedure .................................................................... 436 Lo Beam Headlight Current High Diagnostic Procedure ................................................................... 437 Work Lights Voltage High Diagnostic Procedure ............................................................................... 439 Work Lights Current Low Diagnostic Procedure ................................................................................ 440 Work Lights Voltage Low Diagnostic Procedure ................................................................................ 441 Left Turn Signal Voltage High Diagnostic Procedure ........................................................................ 443 Left Turn Signal Current Low Diagnostic Procedure ......................................................................... 445 Left Turn Signal Current High Diagnostic Procedure ........................................................................ 446 Right Turn Signal Voltage High Diagnostic Procedure ...................................................................... 448 Right Turn Signal Current Low Diagnostic Procedure ....................................................................... 450 Right Turn Signal Current High Diagnostic Procedure ...................................................................... 451 Rotating Beacon Voltage High Diagnostic Procedure ....................................................................... 453 Rotating Beacon Current Low Diagnostic Procedure ........................................................................ 454 Rotating Beacon Current High Diagnostic Procedure ....................................................................... 455 Backup Light and Alarm Voltage High Diagnostic Procedure ............................................................ 457 Backup Light and Alarm Current Low Diagnostic Procedure ............................................................. 459 Backup Light and Alarm Current High Diagnostic Procedure ............................................................ 461 Low Brake Pressure Switch Voltage High Diagnostic Procedure ....................................................... 463 Low Brake Pressure Switch Volage Low Diagnostic Procedure ......................................................... 465 Articulation Reverse Light Voltage High Diagnostic Procedure ........................................................ 467 Articulation Reverse Light Current Low Diagnostic Procedure .......................................................... 468 Articulation Reverse Light Current High Diagnostic Procedure ......................................................... 469 Horn Voltage High Diagnostic Procedure .......................................................................................... 471 Horn Current Low Diagnostic Procedure ........................................................................................... 472 Horn Current High Diagnostic Procedure .......................................................................................... 473 Mirror Heater Voltage High Diagnostic Procedure ............................................................................ 475 Mirror Heater Current Low Diagnostic Procedure ............................................................................. 477 Mirror Heater Current High Diagnostic Procedure ............................................................................ 479 Neutral Mismatch Mechanical Fault Diagnostic Procedure ............................................................... 480 Park Brake Not Holding Diagnostic Procedure .................................................................................. 481 Turn Signal Switch Voltage Low Diagnostic Procedure ..................................................................... 482 Sensor Supply 1 Voltage High Diagnostic Procedure ........................................................................ 484 Sensor Supply 1 Voltage Low Diagnostic Procedure ......................................................................... 485 Sensor Supply 2 Voltage High Diagnostic Procedure ........................................................................ 487 Sensor Supply 2 Voltage Low Diagnostic Procedure ......................................................................... 488 Sensor Supply 3 Voltage High Diagnostic Procedure ........................................................................ 490 Sensor Supply 3 Voltage Low Diagnostic Procedure ......................................................................... 491 HVAC Mode Control Actuator Voltage High Diagnostic Procedure .................................................... 493 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
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HVAC Mode Control Actuator Current High Diagnostic Procedure .................................................... 495 HVAC Recirculation Door Control Actuator Voltage High Diagnostic Procedure ............................... 497 HVAC Recirculation Door Control Actuator Current High Diagnostic Procedure ............................... 499 HVAC Temperature Control Actuator Voltage High Diagnostic Procedure ........................................ 501 HVAC Temperature Control Actuator Current High Diagnostic Procedure ........................................ 503 Fan 2 Reverse Sol Voltage High Diagnostic Procedure ..................................................................... 505 Fan 2 Reverse Sol Current Low Diagnostic Procedure ...................................................................... 506 Fan 2 Reverse Sol Current High Diagnostic Procedure ..................................................................... 507 Fan 2 Speed Very High Diagnostic Procedure .................................................................................. 508 Fan 2 Speed Very Low Diagnostic Procedure ................................................................................... 509 Fan 2 Speed Bad Freq Data Diagnostic Procedure ........................................................................... 511 Fan 2 Solenoid Voltage High Diagnostic Procedure .......................................................................... 513 Fan 2 Solenoid Current Low Diagnostic Procedure ........................................................................... 514 Fan 2 Solenoid Current High Diagnostic Procedure .......................................................................... 515 Fan 2 Current Moderately High Diagnostic Procedure ...................................................................... 517 Fan 2 Voltage Slightly Low Diagnostic Procedure ............................................................................. 519 Fan 2 Voltage Moderately Low Diagnostic Procedure ....................................................................... 520 12V Power Converter Voltage High Diagnostic Procedure ................................................................ 522 12V Power Converter Voltage Low Diagnostic Procedure ................................................................. 524 OBW Strain Gauge Error Diagnostic Procedure ................................................................................ 526 Converter Output Voltage Low Diagnostic Procedure ....................................................................... 528 Intermittent Configuration Error Diagnostic Procedure .................................................................... 529 HVAC Blower HI Speed Current Low Diagnostic Procedure ............................................................... 530 HVAC Blower HI Speed Current High Diagnostic Procedure .............................................................. 532 HVAC Blower Medium Speed Current Low Diagnostic Procedure ..................................................... 534 HVAC Blower Medium Speed Current High Diagnostic Procedure .................................................... 536 HVAC Blower Low Speed Current Low Diagnostic Procedure ............................................................ 538 HVAC Blower Low Speed Current High Diagnostic Procedure ........................................................... 540 Body Raise Solenoid Voltage High Diagnostic Procedure ................................................................. 542 Body Raise Solenoid Current Low Diagnostic Procedure .................................................................. 544 Body Raise Solenoid Current High Diagnostic Procedure ................................................................. 545 Body Raise Solenoid Moderately High Diagnostic Procedure ............................................................ 547 Body Raise Solenoid Slightly Low Diagnostic Procedure ................................................................... 549 Body Raise Solenoid Moderately Low Diagnostic Procedure ............................................................. 550 Mid Axle Oil Filter Restricted Diagnostic Procedure .......................................................................... 551 Mid Axle Oil Filter Voltage High Diagnostic Procedure ...................................................................... 552 Mid Axle Oil Filter Stuck Open Diagnostic Procedure ........................................................................ 552 Rear Axle Oil Filter Restricted Diagnostic Procedure ........................................................................ 553 Rear Axle Oil Filter Voltage High Diagnostic Procedure .................................................................... 555 Rear Axle Oil Filter Stuck Open Diagnostic Procedure ...................................................................... 555 Front Axle CDL Pressure Very High Diagnostic Procedure ................................................................ 557 Front Axle CDL Pressure Very Low Diagnostic Procedure ................................................................. 559 Mid Axle CDL Pressure Very High Diagnostic Procedure ................................................................... 561 Front Axle CDL Pressure Very Low Diagnostic Procedure ................................................................. 563 Rear Axle CDL Pressure Very High Diagnostic Procedure ................................................................. 565 Rear Axle CDL Pressure Very Low Diagnostic Procedure .................................................................. 567 Body Down Solenoid Moderately High Diagnostic Procedure ........................................................... 569 Body Down Solenoid Slightly Low Diagnostic Procedure .................................................................. 571 Body Down Solenoid Moderately Low Diagnostic Procedure ............................................................ 572 Front CDL Solenoid Voltage High Diagnostic Procedure ................................................................... 574 Front CDL Solenoid Current Low Diagnostic Procedure .................................................................... 575 Front CDL Solenoid Current High Diagnostic Procedure ................................................................... 577 Middle CDL Solenoid Voltage High Diagnostic Procedure ................................................................. 579 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
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Middle CDL Solenoid Current Low Diagnostic Procedure .................................................................. 580 Middle CDL Solenoid Current High Diagnostic Procedure ................................................................. 582 Rear CDL Solenoid Voltage High Diagnostic Procedure .................................................................... 584 Rear CDL Solenoid Current Low Diagnostic Procedure ..................................................................... 585 Rear CDL Solenoid Current High Diagnostic Procedure .................................................................... 587 Body Heat Solenoid Voltage High Diagnostic Procedure .................................................................. 589 Body Heat Solenoid Current Low Diagnostic Procedure ................................................................... 590 Body Heat Solenoid Current High Diagnostic Procedure .................................................................. 591 Body Lever Solenoid Voltage High Diagnostic Procedure ................................................................. 593 Body Lever Solenoid Current Low Diagnostic Procedure .................................................................. 595 Body Lever Solenoid Current High Diagnostic Procedure ................................................................. 596 Yellow OBW Light Voltage High Diagnostic Procedure ...................................................................... 598 Yellow OBW Light Current Low Diagnostic Procedure ....................................................................... 600 Yellow OBW Light Current High Diagnostic Procedure ...................................................................... 601 Green OBW Light Voltage High Diagnostic Procedure ...................................................................... 603 Green OBW Light Current Low Diagnostic Procedure ....................................................................... 605 Green OBW Light Current High Diagnostic Procedure ...................................................................... 606 Red OBW Light Voltage High Diagnostic Procedure .......................................................................... 608 Red OBW Light Current Low Diagnostic Procedure ........................................................................... 610 Red OBW Light Current High Diagnostic Procedure .......................................................................... 611 Axle Cooling Cutoff Solenoid Voltage High Diagnostic Procedure ..................................................... 613 Axle Cooling Cutoff Solenoid Current Low Diagnostic Procedure ...................................................... 614 Axle Cooling Cutoff Solenoid Current High Diagnostic Procedure ..................................................... 615 Axle Cooling Cutoff Solenoid Current High Diagnostic Procedure ..................................................... 617 Axle Cooling Cutoff Solenoid Current Low Diagnostic Procedure ...................................................... 619 Axle Cooling Cutoff Solenoid Voltage High Diagnostic Procedure ..................................................... 620 Fan 2 Cutoff Solenoid Voltage High Diagnostic Procedure ............................................................... 621 Fan 2 Cutoff Solenoid Current Low Diagnostic Procedure ................................................................. 622 Fan 2 Cutoff Solenoid Current High Diagnostic Procedure ................................................................ 623 Load Hold Solenoid Voltage High Diagnostic Procedure ................................................................... 625 Load Hold Solenoid Current Low Diagnostic Procedure .................................................................... 626 Load Hold Solenoid Current High Diagnostic Procedure ................................................................... 627 Left Strut Position Sensor Voltage High Diagnostic Procedure ......................................................... 629 Left Strut Position Sensor Voltage Low Diagnostic Procedure .......................................................... 631 Right Strut Position Sensor Voltage High Diagnostic Procedure ....................................................... 633 Right Strut Position Sensor Voltage Low Diagnostic Procedure ........................................................ 635 Body Pressure Reducing Solenoid Voltage High Diagnostic Procedure ............................................ 637 Body Pressure Reducing Solenoid Current Low ................................................................................ 638 Body Pressure Reducing Solenoid Current High Diagnostic Procedure ............................................. 639 Body Pressure Reducing Solenoid Moderately High Diagnostic Procedure ....................................... 641 Body Pressure Reducing Solenoid Slightly Low Diagnostic Procedure .............................................. 643 Body Pressure Reducing Solenoid Moderately Low Diagnostic Procedure ........................................ 644 Service Light Switch Voltage Low Diagnostic Procedure .................................................................. 646 Body Lever Position Sensor Voltage High Diagnostic Procedure ...................................................... 648 Body Lever Position Sensor Voltage Low Diagnostic Procedure ....................................................... 650 Body Position Sensor Voltage High Diagnostic Procedure ................................................................ 651 Body Position Sensor Voltage Low Diagnostic Procedure ................................................................. 653 IDL Solenoid Driver Solenoid Voltage High Diagnostic Procedure .................................................... 655 IDL Solenoid Driver Solenoid Current Low Diagnostic Procedure ..................................................... 657 IDL Solenoid Driver Solenoid Current High Diagnostic Procedure ..................................................... 659 Left Strut Raise Solenoid Voltage High Diagnostic Procedure .......................................................... 661 Left Strut Raise Solenoid Current Low Diagnostic Procedure ........................................................... 663 Left Strut Raise Solenoid Current High Diagnostic Procedure .......................................................... 664 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Left Strut Raise Solenoid Moderately High Diagnostic Procedure ..................................................... 666 Left Strut Raise Solenoid Slightly Low Diagnostic Procedure ............................................................ 668 Left Strut Raise Solenoid Moderately Low Diagnostic Procedure ...................................................... 669 Left Strut Lower Solenoid Moderately High Diagnostic Procedure .................................................... 671 Left strut Lower Solenoid Slightly Low Diagnostic Procedure ........................................................... 673 Left Strut Lower Solenoid Moderately Low Diagnostic Procedure ..................................................... 674 Right Strut Raise Solenoid Voltage High Diagnostic Procedure ........................................................ 676 Right Strut Raise Solenoid Current Low Diagnostic Procedure ......................................................... 678 Right Strut Raise Solenoid Current High Diagnostic Procedure ........................................................ 679 Right Strut Raise Solenoid Moderately High Diagnostic Procedure .................................................. 681 Right Strut Raise Solenoid Slightly Low Diagnostic Procedure ......................................................... 683 Right Strut Raise Solenoid Moderately Low Diagnostic Procedure ................................................... 684 Right Strut Lower Solenoid Moderately High Diagnostic Procedure .................................................. 686 Right Strut Lower Solenoid Slightly Low Diagnostic Procedure ......................................................... 688 Right Strut Lower Solenoid Moderately Low Diagnostic Procedure ................................................... 689 Park Brake Release Valve Voltage High Diagnostic Procedure ......................................................... 691 Park Brake Release Valve Current Low Diagnostic Procedure .......................................................... 693 Park Brake Release Valve Current High Diagnostic Procedure ......................................................... 694 High Beam Switch Voltage Low Diagnostic Procedure ..................................................................... 696 Hazard Lamp Enable Voltage Low Diagnostic Procedure .................................................................. 698 Exit Light Switch Voltage Low Diagnostic Procedure ........................................................................ 699 Park Brake Light Circuit Voltage High Diagnostic Procedure ............................................................ 701 Park Brake Light Circuit Current Low Diagnostic Procedure ............................................................. 702 Park Brake Light Circuit Current High Diagnostic Procedure ............................................................ 703 EOL Checksum Error Diagnostic Procedure ...................................................................................... 704 EOL Checksum Error Diagnostic Procedure ...................................................................................... 704 Reversing Fan Mode Solenoid Voltage High Diagnostic Procedure ................................................... 705 Reversing Fan Mode Solenoid Current Low Diagnostic Procedure .................................................... 707 Reversing Fan Mode Solenoid Current High Diagnostic Procedure ................................................... 708 Front Axle Oil Filter Restricted Diagnostic Procedure ....................................................................... 710 Front Axle Oil Filter Voltage High Diagnostic Procedure ................................................................... 712 Front Axle Oil Filter Stuck Open Diagnostic Procedure ..................................................................... 712 Rear Brake High Temperature Diagnostic Procedure ....................................................................... 713 Rear Brake Temperature Sensor Voltage High Diagnostic Procedure .............................................. 715 Rear Brake Temperature Sensor Voltage Low Diagnostic Procedure ............................................... 717 Mid Brake High Temperature Diagnostic Procedure ......................................................................... 718 Mid Brake Temperature Sensor Voltage High Diagnostic Procedure ................................................ 719 Mid Brake Temperature Sensor Voltage Low Diagnostic Procedure ................................................. 721 Front Brake High Temperature Diagnostic Procedure ...................................................................... 722 Front Brake Temperature Sensor Voltage High Diagnostic Procedure .............................................. 723 Front Brake Temperature Sensor Voltage Low Diagnostic Procedure ............................................... 725 Seat Heater Voltage High Diagnostic Procedure .............................................................................. 727 Seat Heater Current Low Diagnostic Procedure ................................................................................ 728 Seat Heater Current High Diagnostic Procedure ............................................................................... 729 Secondary Steering Pressure Very Low Diagnostic Procedure ......................................................... 731 Secondary Steering Pressure Sensor Voltage High Diagnostic Procedure ........................................ 733 Secondary Steering Pressure Sensor Voltage Low Diagnostic Procedure ......................................... 735 Brake Control Valve 2 Voltage High Diagnostic Procedure ............................................................... 737 Brake Control Valve 2 Current Low Diagnostic Procedure ................................................................ 738 Brake Control Valve 2 Current High Diagnostic Procedure ............................................................... 739 Brake Control Valve 2 Moderately High Diagnostic Procedure ......................................................... 741 Brake Control Valve 2 Slightly Low Diagnostic Procedure ................................................................ 743 Brake Control Valve 2 Moderately Low Diagnostic Procedure .......................................................... 744 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Windshield Washer Pump Current Low Diagnostic Procedure .......................................................... 746 Windshield Washer Pump Current High Diagnostic Procedure ......................................................... 747 Windshield Washer Pump Current High Diagnostic Procedure ......................................................... 749 Park Brake Pressure Switch Voltage High Diagnostic Procedure ...................................................... 751 Park Brake Pressure Switch Voltage Low Diagnostic Procedure ....................................................... 752 Front Wiper Park Signal Invalid Diagnostic Procedure ...................................................................... 754 Front Wiper Lo Speed Motor Current Low Diagnostic Procedure ...................................................... 756 Front Wiper Lo Speed Motor Current High Diagnostic Procedure ..................................................... 757 Front Wiper Lo Speed Motor Current Moderately High Diagnostic Procedure ................................... 759 Front Wiper High Speed Motor Current Low Diagnostic Procedure ................................................... 761 Front Wiper High Speed Motor Current High Diagnostic Procedure .................................................. 762 Front Wiper High Speed Motor Current Moderately High Diagnostic Procedure ............................... 764 TC Stall Protection Very High Diagnostic Procedure ......................................................................... 765 VP3 Supply Voltage Low Diagnostic Procedure ................................................................................ 766 VP2 Supply Voltage High Diagnostic Procedure ............................................................................... 767 VP2 Supply Voltage Low Diagnostic Procedure ................................................................................ 768 VP1 Supply Voltage High Diagnostic Procedure ............................................................................... 768 VP1 Supply Voltage Low Diagnostic Procedure ................................................................................ 770 Service Lights Voltage High Diagnostic Procedure ........................................................................... 771 Service Lights Current Low Diagnostic Procedure ............................................................................ 772 Service Lights Current High Diagnostic Procedure ........................................................................... 773 Flexpower Data Bad Update Rate Diagnostic Procedure .................................................................. 774 Flexpower No Information Diagnostic Procedure .............................................................................. 774 Operator Exit Light Voltage High Diagnostic Procedure ................................................................... 776 Operator Exit Light Current Low Diagnostic Procedure .................................................................... 777 Operator Exit Light Current High Diagnostic Procedure ................................................................... 778 Rear Axle Lube Pressure Very Low Diagnostic Procedure ................................................................. 779 Rear Axle Lube Pressure Sensor Voltage High Diagnostic Procedure ............................................... 780 Rear Axle Lube Pressure Sensor Voltage Low Diagnostic Procedure ................................................ 782 Front Axle Lube Pressure Very Low Diagnostic Procedure ................................................................ 784 Front Axle Lube Pressure Sensor Voltage High Diagnostic Procedure .............................................. 785 Front Axle Lube Pressure Sensor Voltage Low Diagnostic Procedure ............................................... 787 M Axle Lube Pressure Very Low Diagnostic Procedure ..................................................................... 788 M Axle Lube Pressure Sensor Voltage High Diagnostic Procedure .................................................... 789 M Axle Lube Pressure Sensor Voltage Low Diagnostic Procedure ..................................................... 791 Transmission Movement in Neutral Diagnostic Procedure ................................................................ 792 Group 40 - CAN Monitor Unit (CMU) Diagnostic Trouble Codes ................................................... 794 ECU CAN Comm Diagnostic Procedure ............................................................................................. 794 TCU CAN Comm Diagnostic Procedure ............................................................................................. 796 CCU CAN Data Fault Diagnostic Procedure ....................................................................................... 798 Group 50 - 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes ................ 800 Controller Fault Bad Device Diagnostic Procedure ........................................................................... 800 CCU CAN Communication Fault Diagnostic Procedure ..................................................................... 801 Ignition Relay Out Voltage Low Diagnostic Procedure ...................................................................... 803 Ignition Relay Out Current Low Diagnostic Procedure ...................................................................... 805 Wake Up Output Voltage Low Diagnostic Procedure ........................................................................ 807 Wake Up Output Current Low ........................................................................................................... 809 Button 17 Voltage Low Diagnostic Procedure ................................................................................... 809 Button 17 Bad Update Rate Diagnostic Procedure ........................................................................... 812 Button 18 Voltage Low Diagnostic Procedure ................................................................................... 813 Button 18 Bad Update Rate Diagnostic Procedure ........................................................................... 815 Button 19 Voltage Low Diagnostic Procedure ................................................................................... 816 Button 19 Bad Update Rate Diagnostic Procedure ........................................................................... 818 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Button 20 Voltage Low Diagnostic Procedure ................................................................................... 819 Button 20 Bad Update Rate Diagnostic Procedure ........................................................................... 821 Button 25 Voltage Low Diagnostic Procedure ................................................................................... 822 Button 25 Bad Update Rate Diagnostic Procedure ........................................................................... 824 Button 24 Voltage Low Diagnostic Procedure ................................................................................... 825 Button 24 Bad Update Rate Diagnostic Procedure ........................................................................... 827 Button 23 Voltage Low Diagnostic Procedure ................................................................................... 828 Button 23 Bad Update Rate Diagnostic Procedure ........................................................................... 830 Button 22 Voltage Low Diagnostic Procedure ................................................................................... 831 Button 22 Bad Update Rate Diagnostic Procedure ........................................................................... 833 Button 21 Voltage Low Diagnostic Procedure ................................................................................... 834 Button 21 Bad Update Rate Diagnostic Procedure ........................................................................... 836 Button 16 Voltage Low Diagnostic Procedure ................................................................................... 837 Button 16 Bad Update Rate Diagnostic Procedure ........................................................................... 839 Button 15 Voltage Low Diagnostic Procedure ................................................................................... 840 Button 15 Bad Update Rate Diagnostic Procedure ........................................................................... 842 Button 14 Voltage Low Diagnostic Procedure ................................................................................... 843 Button 14 Bad Update Rate Diagnostic Procedure ........................................................................... 845 Button 13 Voltage Low Diagnostic Procedure ................................................................................... 846 Button 13 Bad Update Rate Diagnostic Procedure ........................................................................... 848 Button 12 Voltage Low Diagnostic Procedure ................................................................................... 849 Button 12 Bad Update Rate Diagnostic Procedure ........................................................................... 851 Button 11 Voltage Low Diagnostic Procedure ................................................................................... 852 Button 11 Bad Update Rate Diagnostic Procedure ........................................................................... 854 Button 10 Voltage Low Diagnostic Procedure ................................................................................... 855 Button 10 Bad Update Rate Diagnostic Procedure ........................................................................... 857 Button 9 Voltage Low Diagnostic Procedure ..................................................................................... 858 Button 9 Bad Update Rate Diagnostic Procedure ............................................................................. 860 Button 8 Voltage Low Diagnostic Procedure ..................................................................................... 861 Button 8 Bad Update Rate Diagnostic Procedure ............................................................................. 863 Button 7 Voltage Low Diagnostic Procedure ..................................................................................... 864 Button 7 Bad Update Rate Diagnostic Procedure ............................................................................. 866 Button 6 Voltage Low Diagnostic Procedure ..................................................................................... 867 Button 6 Bad Update Rate Diagnostic Procedure ............................................................................. 869 Button 5 Voltage Low Diagnostic Procedure ..................................................................................... 870 Button 5 Bad Update Rate Diagnostic Procedure ............................................................................. 872 Button 4 Voltage Low Diagnostic Procedure ..................................................................................... 873 Button 4 Bad Update Rate Diagnostic Procedure ............................................................................. 875 Button 3 Voltage Low Diagnostic Procedure ..................................................................................... 876 Button 3 Bad Update Rate Diagnostic Procedure ............................................................................. 878 Button 2 Voltage Low Diagnostic Procedure ..................................................................................... 879 Button 2 Bad Update Rate Diagnostic Procedure ............................................................................. 881 Button 1 Voltage Low Diagnostic Procedure ..................................................................................... 882 Button 1 Bad Update Rate Diagnostic Procedure ............................................................................. 884 Group 60 - 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes ................ 886 Controller Fault Bad Device Diagnostic Procedure ........................................................................... 886 CCU CAN Communication Fault Diagnostic Procedure ..................................................................... 887 Button 15 Voltage Low Diagnostic Procedure ................................................................................... 888 Button 15 Bad Update Rate Diagnostic Procedure ........................................................................... 890 Button 14 Voltage Low Diagnostic Procedure ................................................................................... 891 Button 14 Bad Update Rate Diagnostic Procedure ........................................................................... 893 Button 13 Voltage Low Diagnostic Procedure ................................................................................... 894 Button 13 Bad Update Rate Diagnostic Procedure ........................................................................... 896 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Button 12 Voltage Low Diagnostic Procedure ................................................................................... 897 Button 12 Bad Update Rate Diagnostic Procedure ........................................................................... 899 Button 11 Voltage Low Diagnostic Procedure ................................................................................... 900 Button 11 Bad Update Rate Diagnostic Procedure ........................................................................... 902 Button 10 Voltage Low Diagnostic Procedure ................................................................................... 903 Button 10 Bad Update Rate Diagnostic Procedure ........................................................................... 905 Button 9 Voltage Low Diagnostic Procedure ..................................................................................... 906 Button 9 Bad Update Rate Diagnostic Procedure ............................................................................. 908 Button 8 Voltage Low Diagnostic Procedure ..................................................................................... 909 Button 8 Bad Update Rate Diagnostic Procedure ............................................................................. 911 Button 7 Voltage Low Diagnostic Procedure ..................................................................................... 912 Button 7 Bad Update Rate Diagnostic Procedure ............................................................................. 914 Button 6 Voltage Low Diagnostic Procedure ..................................................................................... 915 Button 6 Bad Update Rate Diagnostic Procedure ............................................................................. 917 Button 5 Voltage Low Diagnostic Procedure ..................................................................................... 918 Button 5 Bad Update Rate Diagnostic Procedure ............................................................................. 920 Button 4 Voltage Low Diagnostic Procedure ..................................................................................... 921 Button 4 Bad Update Rate Diagnostic Procedure ............................................................................. 923 Button 3 Voltage Low Diagnostic Procedure ..................................................................................... 924 Button 3 Bad Update Rate Diagnostic Procedure ............................................................................. 926 Button 2 Voltage Low Diagnostic Procedure ..................................................................................... 927 Button 2 Bad Update Rate Diagnostic Procedure ............................................................................. 929 Button 1 Voltage Low Diagnostic Procedure ..................................................................................... 930 Button 1 Bad Update Rate Diagnostic Procedure ............................................................................. 932
<- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Group 10 - Transmission Control Unit (TCU) Diagnostic Trouble Codes 523000.01- Battery Low Undervoltage 44
The TCU detects battery voltage at or below 18 volts.
Battery Low Undervoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Fuse Check. ( 2 ) Fuse Check
Action: Access cab fuses. See Fuse and Relay Specifications . (Group 9015-10.) Remove fuses F11 and F25 and check for continuity. Is continuity indicated across both fuses?
Result: YES:Go to Battery Check. NO:Replace fuse without continuity. ( 3 ) Battery Check
Action: Check battery terminals for proper connection and check batteries for voltage separately. See Handling, Checking and Servicing Batteries Carefully . (Operator’s Manual.) Do batteries test good?
Result: YES:Go to Connector Check. NO:Replace batteries. ( 4 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connector for corrosion and terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Does connector test good?
Result: YES:Go to Ground Check. NO:Repair or replace connector. <- Go to Section TOC
Section 9001 page 1
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
( 5 ) Ground Check
Action: Check for ground between ground terminal (B-) of alternator and machine ground. Is ground present?
Result: YES:Go to Voltage Check. NO:Open ground circuit. Repair circuit. ( 6 ) Voltage Check
Action: Check for system voltage between supply terminal (B+) of alternator and machine ground. Is system voltage present?
Result: YES:Go to Component Check. NO:Open supply circuit. Repair circuit. ( 7 ) Component Check
Action: Check the serpentine belt for proper tension and performance. See Inspect Serpentine Belt . (Operator′s Manual.) Does the serpentine belt test good?
Result: YES:Go to Alternator Check. NO:Replace the serpentine belt. See Serpentine Belt Remove and Install . (Group 0510.) ( 8 ) Alternator Check
Action: Perform Alternator Test . (Group 9015-20.) Does alternator test good?
Result: YES:Program transmission control unit (TCU). NO:Replace alternator. 523000.03- Battery Overvoltage 44
The TCU detects battery voltage at or above 32.50 volts.
Battery Overvoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-05.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”? <- Go to Section TOC
Section 9001 page 2
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-15.) NO:Go to Ground Check. ( 2 ) Ground Check
Action: Check for ground between ground terminal (B-) of alternator and machine ground. Is ground present?
Result: YES:Go to Voltage Check. NO:Open ground circuit. Repair circuit. ( 3 ) Voltage Check
Action: Start engine. Check voltage at batteries. Are 32.50 volts or more present?
Result: YES:Go to Alternator Check. NO:Program transmission control unit (TCU). ( 4 ) Alternator Check
Action: Perform Alternator Test . (Group 9015-25.) Does alternator test good?
Result: YES:Checks complete. NO:Replace alternator.
<- Go to Section TOC
Section 9001 page 3
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523000.04- Battery Undervoltage 44
The TCU detects low battery voltage.
Battery Undervoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-05.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-15.) NO:Go to Fuse Check. ( 2 ) Fuse Check
Action: Access cab fuses. See Fuse and Relay Specifications . (Group 9015-10.) Remove fuses F11 and F25 and check for continuity. Is continuity indicated across both fuses?
Result: YES:Go to Battery Check. NO:Replace fuse without continuity. ( 3 ) Battery Check
Action: Check battery terminals for proper connection and check batteries for voltage separately. See Handling, Checking and Servicing Batteries Carefully . (Operator′s Manual.) Do batteries test good?
Result: YES:Go to Connector Check. NO:Replace batteries. ( 4 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connector for corrosion and terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Does connector test good?
Result: YES:Go to Ground Check. NO:Repair or replace connector. ( 5 ) Ground Check <- Go to Section TOC
Section 9001 page 4
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Action: Check for ground between ground terminal (B-) of alternator and machine ground. Is ground present?
Result: YES:Go to Voltage Check. NO:Open ground circuit. Repair circuit. ( 6 ) Voltage Check
Action: Check for system voltage between supply terminal (B+) of alternator and machine ground. Is system voltage present?
Result: YES:Go to Component Check. NO:Open supply circuit. Repair circuit. ( 7 ) Component Check
Action: Check the serpentine belt for proper tension and performance. See Inspect Serpentine Belt . (Operator′s Manual.) Does the serpentine belt test good?
Result: YES:Go to Alternator Check. NO:Replace the serpentine belt. See Serpentine Belt Remove and Install . (Group 0510.) ( 8 ) Alternator Check
Action: Perform Alternator Test . (Group 9015-20.) Does alternator test good?
Result: YES:Program transmission control unit (TCU). NO:Replace alternator.
<- Go to Section TOC
Section 9001 page 5
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523001.01- Battery Undervoltage During Engine Start 44
The TCU detects low battery voltage during engine start.
Battery Undervoltage During Engine Start Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Fuse Check. ( 2 ) Fuse Check
Action: Access cab fuses. See Fuse and Relay Specifications . (Group 9015-10.) Remove fuses F11 and F25 and check for continuity. Is continuity indicated across both fuses?
Result: YES:Go to Battery Check. NO:Replace fuse without continuity. ( 3 ) Battery Check
Action: Check battery terminals for proper connection and check batteries for voltage separately. See Handling, Checking and Servicing Batteries Carefully . (Operator′s Manual.) Do batteries test good?
Result: YES:Go to Connector Check. NO:Replace batteries. ( 4 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connector for corrosion and terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Does connector test good?
Result: YES:Go to Ground Check. NO:Repair or replace connector. ( 5 ) Ground Check <- Go to Section TOC
Section 9001 page 6
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Action: Check for ground between ground terminal (B-) of alternator and machine ground. Is ground present?
Result: YES:Go to Voltage Check. NO:Open ground circuit. Repair circuit. ( 6 ) Voltage Check
Action: Check for system voltage between supply terminal (B+) of alternator and machine ground. Is system voltage present?
Result: YES:Go to Component Check. NO:Open supply circuit. Repair circuit. ( 7 ) Component Check
Action: Check the serpentine belt for proper tension and performance. See Inspect Serpentine Belt . (Operator′s Manual.) Does the serpentine belt test good?
Result: YES:Go to Alternator Check. NO:Replace the serpentine belt. See Serpentine Belt Remove and Install . (Group 0510.) ( 8 ) Alternator Check
Action: Perform Alternator Test . (Group 9015-20.) Does alternator test good?
Result: YES:Program transmission control unit (TCU). NO:Replace alternator.
<- Go to Section TOC
Section 9001 page 7
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523010.03- EC-II Internal 5V Power Supply Overvoltage 44
The 5 volt supply circuit for the solenoid valves is short to power.
EC-II Internal 5V Power Supply Overvoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect output speed sensor (B43). See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Ignition ON. Check circuit ORG for voltage at pin 1 of output speed sensor (B43) connector. Are 6.5 volts or more present?
Result: YES:Go to next check. NO:Go to Harness Check.
Action: Ignition OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Ignition ON. Check circuit 0310 for voltage at pin 10 on harness (W5) side of connector (X72). Are 6.5 volts or more present?
Result: YES:Circuit 0310 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Circuit ORG is short to power inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . <- Go to Section TOC
Section 9001 page 8
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
(Group 9015-10.) Check for continuity between pin 14 (circuit 0310) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0310 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 10 (circuit ORG) of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 9
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523010.04- EC-II Internal 5V Power Supply Undervoltage 44
The 5 volt supply circuit for the solenoid valves is short to power.
EC-II Internal 5V Power Supply Undervoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Open Circuit Check. ( 2 ) Open Circuit Check
Action: Ignition OFF. Disconnect output speed sensor (B43). See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit ORG) of output speed sensor (B43) and pin 14 (circuit 0310) on TCU connector (X71). Is continuity indicated?
Result: YES:Program transmission control unit (TCU). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check circuit 0310 for continuity between pin 10 on harness (W4) side of connector (X72) and pin 14 on harness (W4) side of connector (X71). Is continuity indicated?
Result: YES:Circuit ORG is open inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Circuit 0310 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 10
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523011.04- EC-II Internal 7V Power Supply Undervoltage 44
The 7 volt supply circuit for the solenoid valves is short to power.
EC-II Internal 7V Power Supply Undervoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Open Circuit Check. ( 2 ) Open Circuit Check
Action: Ignition OFF. Disconnect output speed sensor (B43). See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit ORG) of output speed sensor (B43) and pin 14 (circuit 0310) on TCU connector (X71). Is continuity indicated?
Result: YES:Program transmission control unit (TCU). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check circuit 0310 for continuity between pin 10 on harness (W4) side of connector (X72) and pin 14 on harness (W4) side of connector (X71). Is continuity indicated?
Result: YES:Circuit ORG is open inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Circuit 0310 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 11
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523020.03- Speed Sensor Supply Overvoltage 44
The 6.5 volt supply circuit for the speed sensors is short to power.
Speed Sensor Supply Overvoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect output speed sensor (B43). See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Ignition ON. Check circuit ORG for voltage at pin 1 of output speed sensor (B43) connector. Are 6.5 volts or more present?
Result: YES:Go to next check. NO:Go to Harness Check.
Action: Ignition OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Ignition ON. Check circuit 0310 for voltage at pin 10 on harness (W5) side of connector (X72). Are 6.5 volts or more present?
Result: YES:Circuit 0310 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Circuit ORG is short to power inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . <- Go to Section TOC
Section 9001 page 12
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
(Group 9015-10.) Check for continuity between pin 14 (circuit 0310) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0310 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 10 (circuit ORG) of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
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Section 9001 page 13
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523020.04- Speed Sensor Supply Undervoltage 44
The 6.5 volt supply circuit for the speed sensors is open.
Speed Sensor Supply Undervoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Open Circuit Check. ( 2 ) Open Circuit Check
Action: Ignition OFF. Disconnect output speed sensor (B43). See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit ORG) of output speed sensor (B43) and pin 14 (circuit 0310) on TCU connector (X71). Is continuity indicated?
Result: YES:Program transmission control unit (TCU). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check circuit 0310 for continuity between pin 10 on harness (W4) side of connector (X72) and pin 14 on harness (W4) side of connector (X71). Is continuity indicated?
Result: YES:Circuit ORG is open inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Circuit 0310 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 14
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523020.06- Speed Sensor Voltage Low 44
The 6.5 volt supply circuit for the speed sensors is short to ground.
Speed Sensor voltage Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect output speed sensor (B43). See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Check circuit ORG for ground at pin 1 of output speed sensor (B43) connector. Is ground present?
Result: YES:Go to next check. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check.
Action: Ignition OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check circuit 0310 for ground at pin 10 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0310 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Circuit ORG is short to ground inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 15
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Check for continuity between pin 14 (circuit 0310) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0310 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 10 (circuit ORG) on harness (W5) side of connector (X72) and all other pins on connectors (X72). Is continuity indicated?
Result: YES:Circuit ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
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Section 9001 page 16
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523021.03- Temp/Oil Filt Supply Overvoltage 44
The 6.3 volt supply circuit for the oil filter restriction switch is short to power.
Temp/Oil Filt Supply Overvoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of transmission filter restriction switch (B17). Are approximately 510 ohms present?
Result: YES:Go to Short Circuit Check. NO:Replace transmission filter restriction switch (B17). ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit G12 BLK for voltage at pin 1 of transmission filter restriction switch (B17) connector. Are 6.3 volts or more present?
Result: YES:Circuit G12 BLK and/or 0201 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 24 (circuit 0201 ) on TCU connector (X71) and all other pins on TCU connectors (X70 and <- Go to Section TOC
Section 9001 page 17
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
X71). Is continuity indicated?
Result: YES:Circuit G12 BLK and/or 0201 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 18
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523021.04- Temp/Oil Filt Supply Undervoltage 44
The 6.3 volt supply circuit for the oil filter restriction switch is open.
Temp/Oil Filt Supply Undervoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of transmission filter restriction switch (B17). Are approximately 510 ohms present?
Result: YES:Go to Open Circuit Check. NO:Replace transmission filter restriction switch (B17). ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit G12 BLK) of transmission filter restriction switch (B17) and pin 24 (circuit 0201) on TCU connector (X71). Is continuity indicated?
Result: YES:Circuit G12 BLK and/or 0201 is open. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 19
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523021.06- Temp/Oil Filt Supply Voltage Low 44
The 6.3 volt supply circuit for the transmission filter restriction switch is short to ground.
Temp/Oil Filt Supply Voltage Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of transmission filter restriction switch (B17). Are approximately 510 ohms present?
Result: YES:Go to Short Circuit Check. NO:Replace filter restriction switch (B17). ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check circuit G12 BLK for ground at pin 1 of transmission filter restriction switch (B17) connector. Is ground present?
Result: YES:Circuit G12 BLK and/or 0201 is short to ground. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 24 (circuit 0201) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
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Section 9001 page 20
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Circuit G12 BLK and/or 0201 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 21
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523022.03- Supply 1 For Sensors Overvoltage 44
The 6.5 volt supply circuit for the speed sensors is short to power.
Supply 1 For Sensors Overvoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect output speed sensor (B43). See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Ignition ON. Check circuit ORG for voltage at pin 1 of output speed sensor (B43) connector. Are 6.5 volts or more present?
Result: YES:Go to next check. NO:Go to Harness Check.
Action: Ignition OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Ignition ON. Check circuit 0310 for voltage at pin 10 on harness (W5) side of connector (X72). Are 6.5 volts or more present?
Result: YES:Circuit 0310 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Circuit ORG is short to power inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . <- Go to Section TOC
Section 9001 page 22
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
(Group 9015-10.) Check for continuity between pin 14 (circuit 0310) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0310 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 10 (circuit ORG) of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 23
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523022.04- Supply 1 For Sensors Undervoltage 44
The 6.5 volt supply circuit for the speed sensors is open.
Supply 1 For Sensors Undervoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Open Circuit Check. ( 2 ) Open Circuit Check
Action: Ignition OFF. Disconnect output speed sensor (B43). See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit ORG) of output speed sensor (B43) and pin 14 (circuit 0310) on TCU connector (X71). Is continuity indicated?
Result: YES:Program transmission control unit (TCU). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check circuit 0310 for continuity between pin 10 on harness (W4) side of connector (X72) and pin 14 on harness (W4) side of connector (X71). Is continuity indicated?
Result: YES:Circuit ORG is open inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Circuit 0310 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 24
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523022.06- Supply 1 For Sensors Short to Ground 44
The 6.5 volt supply circuit for the speed sensors is short to ground.
Supply 1 For Sensors Short to Ground Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect output speed sensor (B43). See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Check circuit ORG for ground at pin 1 of output speed sensor (B43) connector. Is ground present?
Result: YES:Go to next check. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check.
Action: Ignition OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check circuit 0310 for ground at pin 10 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0310 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Circuit ORG is short to ground inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 25
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Check for continuity between pin 14 (circuit 0310) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0310 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 10 (circuit ORG) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 26
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523030.03- Propvalve Supply 1 Overvoltage 44
The supply circuit for the transmission clutch solenoids is short to power.
Propvalve Supply 1 Overvoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0323 for voltage at pin 23 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0101 and/or 0323 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 1 (circuit 0101) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0101 and/or 0323 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 23 (circuit RED) on harness (W5) side of connector (X72) and all other pins on connector (X72). <- Go to Section TOC
Section 9001 page 27
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU). 523030.04- Propvalve Supply 1 Undervoltage 44
The supply circuit for the transmission clutch solenoids is open.
Propvalve Supply 1 Undervoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Open Circuit Check. ( 2 ) Open Circuit Check
Action: Ignition OFF. Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit 0101) of connector (X71) and pin 23 (circuit 0323) on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Circuit 0101 and/or 0323 is open inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Circuit 0101 and/or 0323 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 28
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523030.06- VPS1 Power Supply Voltage Low 44
The supply circuit for the transmission clutch solenoids is short to ground.
VPS1 Power Supply Voltage Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0323 for ground at pin 23 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0323 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 1 (circuit 0101) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0101 and/or 0323 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 23 (circuit RED) on harness (W5) side of connector (X72) and all other pins on TCU connector (X72). Is continuity indicated? <- Go to Section TOC
Section 9001 page 29
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Circuit RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 30
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523031.03- Propvalve Supply 2 Overvoltage 44
The supply circuit for the lockup solenoids is short to power.
Propvalve Supply 2 Overvoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0324 for voltage at pin 24 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0324 and/or 0102 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 2 (circuit 0102) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0324 and/or 0102 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 24 (circuit ORG) on harness (W5) side of connector (X72) and all other pins on TCU connector (X72). <- Go to Section TOC
Section 9001 page 31
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU). 523031.04- Propvalve Supply 2 Undervoltage 44
The supply circuit for the lockup solenoids is open.
Propvalve Supply 2 Undervoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Open Circuit Check. ( 2 ) Open Circuit Check
Action: Ignition OFF. Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check for continuity between pin 2 (circuit 0101) of connector (X71) and pin 24 (circuit ORG) on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Circuit ORG is open inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Circuit 0324 and/or 0102 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 32
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523031.06- VPS2 Power Supply Voltage Low 44
The supply circuit for the lockup solenoids is short to ground.
VPS2 Power Supply Voltage Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect torque converter lockup (WK) solenoid (Y68) and retarder solenoid (Y69). Measure between pin 2 of solenoids (Y68 and Y69) and machine ground. Disconnect inter-axle differential lock (IDL) solenoid (Y70). Measure between pin B of solenoid (Y70) and machine ground. Is ground present?
Result: YES:Solenoid is short to ground. Replace solenoid. NO:Go to Short Circuit Check. ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0324 for ground at pin 24 on TCU side of connector (X72). Is ground present?
Result: YES:Circuit 0324 and/or 0102 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check circuit ORG for ground at pin 24 on harness (W5) side of connector (X72). Is ground present?
<- Go to Section TOC
Section 9001 page 33
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Circuit ORG is short to ground inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 2 (circuit 0102) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0324 and/or 0102 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 24 (circuit ORG) of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU). 523040.00- TCU Overtemp 44
The internal measured temperature on the transmission control unit (TCU) is too high.
TCU Overtemp Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Are high temperature components near TCU. <- Go to Section TOC
Section 9001 page 34
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Move high temperature components away from TCU. NO:Go to Cycle Ignition Check. ( 3 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523040.00 present?
Result: YES:Program transmission control unit (TCU). NO:Checks complete. 523040.02- TCU Temp Invalid 44
The internal measured temperature on the transmission control unit (TCU) is invalid.
TCU Temp Invalid Diagnostic Procedure Alarm Level: Check Service Code Icon Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523040.02 present?
Result: YES:Program transmission control unit (TCU). NO:Checks complete. 523045.12- Internal Error 1 44
The transmission control unit detects an internal error.
Internal Error 1 Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: <- Go to Section TOC
Section 9001 page 35
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523045.12 present?
Result: YES:Program transmission control unit (TCU). NO:Checks complete. 523046.12- Internal Error 2 44
The transmission control unit detects an internal error.
Internal Error 2 Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523046.12 present?
Result: YES:Program transmission control unit (TCU). NO:Checks complete. 523047.12- Internal Error 3 <- Go to Section TOC
Section 9001 page 36
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
44
The transmission control unit detects an internal error.
Internal Error 3 Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523047.12 present?
Result: YES:Program transmission control unit (TCU). NO:Checks complete. 523048.12- Internal Error 4 44
The transmission control unit detects an internal error.
Internal Error 4 Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523048.12 present? <- Go to Section TOC
Section 9001 page 37
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Checks complete. 523049.12- Unknown TCU Hardware Detected 44
The transmission control unit (TCU) detects an unknown hardware input.
Unknown Transmission Control Unit (TCU) Hardware Detected Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523049.12 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523049.12 and check diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Program transmission control unit (TCU). NO:Repair or replace connectors.
<- Go to Section TOC
Section 9001 page 38
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523100.02- Turbine Speed Unknown Input 44
The transmission control unit (TCU) detects an unknown electrical component at the turbine speed input.
Turbine Speed Unknown Input Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523100.03 or 523100.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523100.03 and/or 523100.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace turbine speed sensor (B40). <- Go to Section TOC
Section 9001 page 39
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 40
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523100.03- Turbine Speed Sensor Input Overvoltage 44
The turbine speed sensor is short to power.
Turbine Speed Sensor Input Overvoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0313 for voltage at pin 13 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0313 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 15 (circuit 0313) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0313 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 13 (circuit GRY) on harness (W5) side of connector (X72) and all other pins on connector (X72). <- Go to Section TOC
Section 9001 page 41
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit GRY is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 42
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523100.06- Turbine Speed Sensor Voltage Low 44
The turbine speed sensor is open or short to ground.
Turbine Speed Sensor Voltage Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0313 for ground at pin 13 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0313 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check circuit GRY for ground at pin 13 on harness (W5) side of connector (X72). Is ground present?
Result: YES:Circuit GRY is short to ground inside transmission on clutch control harness (W5). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 3 ) Open Circuit Check
Action: Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 15 (circuit 0313) on TCU connector (X71) and pin 13 on harness (W4) side of connector (X72). Is continuity indicated?
<- Go to Section TOC
Section 9001 page 43
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Go to next check. NO:Circuit 0313 is open. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
Action: Remove solenoid access cover from top of transmission. Disconnect turbine speed sensor (B40). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for continuity between pin 13 (circuit GRY) of connector (X72) and pin 2 on turbine speed sensor (B40) connector. Check for continuity between pin 10 (circuit ORG) of connector (X72) and pin 1 on turbine speed sensor (B40) connector. Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuits without continuity are open. Repair circuits or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 15 (circuit 0313) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0313 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 13 (circuit GRY) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit GRY is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Replace turbine speed sensor (B40).
<- Go to Section TOC
Section 9001 page 44
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523100.07- Turbine Speed Input Speed Mismatch 44
The turbine speed sensor speed data does not match the other speed sensors measured values.
Turbine Speed Input Speed Mismatch Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523100.03 or 523100.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523100.03 and/or 523100.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace turbine speed sensor (B40). <- Go to Section TOC
Section 9001 page 45
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 46
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523100.08- Turbine Speed Error ROT DIR Unknown 44
The transmission control unit (TCU) does not recognize the rotation direction of the turbine speed sensor.
Turbine Speed Error ROT DIR Unknown Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523100.03 or 523100.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523100.03 and/or 523100.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace turbine speed sensor (B40). <- Go to Section TOC
Section 9001 page 47
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 48
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523100.09- Turbine Speed Error Speed Unknown 44
The turbine speed sensor data is unknown at the transmission control unit (TCU).
Turbine Speed Error Speed Unknown Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523100.03 or 523100.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523100.03 and/or 523100.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace turbine speed sensor (B40). <- Go to Section TOC
Section 9001 page 49
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 50
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523100.11- Turbine Speed Error ROT DIR Mismatch 44
The turbine speed sensor rotation data does not match the other speed sensors measured values.
Turbine Speed Error ROT DIR Mismatch Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523100.03 or 523100.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523100.03 and/or 523100.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace turbine speed sensor (B40). <- Go to Section TOC
Section 9001 page 51
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 52
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523105.02- Speed Sensor 1 Unknown Input 44
The transmission control unit (TCU) detects an unknown electrical component at clutch A primary speed sensor input.
Speed Sensor 1 Unknown Input Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523105.03 or 523105.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523105.03 and/or 523105.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace clutch A primary speed sensor (B41). <- Go to Section TOC
Section 9001 page 53
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 54
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523105.03- Speed Sensor 1 Overvoltage 44
The clutch A primary speed sensor is short to power.
Speed Sensor 1 Overvoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0311 for voltage at pin 11 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0311 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 16 (circuit 0311) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0311 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 11 (circuit GRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). <- Go to Section TOC
Section 9001 page 55
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 56
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523105.06- Speed Sensor 1 Voltage Low 44
The clutch A primary speed sensor is open or short to ground.
Speed Sensor 1 Voltage Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0311 for ground at pin 11 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0311 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check circuit GRN for ground at pin 11 on harness (W5) side of connector (X72). Is ground present?
Result: YES:Circuit GRN is short to ground inside transmission on clutch control harness (W5). Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 3 ) Open Circuit Check
Action: Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 16 (circuit 0311) on TCU connector (X71) and pin 11 on transmission control harness-totransmission valve control harness connector (X72). Is continuity indicated?
<- Go to Section TOC
Section 9001 page 57
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Go to next check. NO:Circuit 0311 is open. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
Action: Remove solenoid access cover from top of transmission. Disconnect clutch A primary speed sensor (B41). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for continuity between pin 11 (circuit GRN) on harness (W5) side of connector (X72) and pin 2 on clutch A primary speed sensor (B41) connector. Check for continuity between pin 10 (circuit ORG) on harness (W5) side of connector (X72) and pin 1 on clutch A primary speed sensor (B41) connector. Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuits without continuity are open. Repair circuits or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 16 (circuit 0311) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0311 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 11 (circuit GRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Replace clutch A primary speed sensor (B41).
<- Go to Section TOC
Section 9001 page 58
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523105.07- Speed Sensor 1 Speed Mismatch 44
The clutch A primary speed sensor data does not match the other speed sensors measured values.
Speed Sensor 1 Speed Mismatch Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523105.03 or 523105.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523105.03 and/or 523105.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace clutch A primary speed sensor (B41). <- Go to Section TOC
Section 9001 page 59
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 60
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523105.08- Speed Sensor 1 DIR ROT Unknown 44
The transmission control unit (TCU) does not recognize the rotation direction of the clutch A primary speed sensor.
Speed Sensor 1 DIR ROT Unknown Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523105.03 or 523105.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523105.03 and/or 523105.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace clutch A primary speed sensor (B41). <- Go to Section TOC
Section 9001 page 61
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 62
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523105.09- Speed Sensor 1 Speed Unknown 44
The clutch A primary speed sensor data is unknown at the transmission control unit (TCU).
Speed Sensor 1 Speed Unknown Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523105.03 or 523105.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523105.03 and/or 523105.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace clutch A primary speed sensor (B41). <- Go to Section TOC
Section 9001 page 63
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 64
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523105.11- Speed Sensor 1 DIR ROT Mismatch 44
The clutch A primary speed sensor rotation data does not match the other speed sensors measured values.
Speed Sensor 1 DIR ROT Mismatch Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523105.03 or 523105.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523105.03 and/or 523105.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace clutch A primary speed sensor (B41). <- Go to Section TOC
Section 9001 page 65
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 66
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523110.02- Speed Sensor 2 Unknown Input 44
The transmission control unit (TCU) detects an unknown electrical component at the clutch C secondary speed sensor.
Speed Sensor 2 Unknown Input Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523110.03 or 523110.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523110.03 and/or 523110.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace clutch C secondary speed sensor (B42). <- Go to Section TOC
Section 9001 page 67
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 68
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523110.03- Speed Sensor 2 Overvoltage 44
The clutch C secondary speed sensor is short to power.
Speed Sensor 2 Overvoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0312 for voltage at pin 12 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0312 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 17 (circuit 0312) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0312 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 12 (circuit YEL) on harness (W5) side of connector (X72) and all other pins on connector (X72). <- Go to Section TOC
Section 9001 page 69
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Replace clutch C secondary speed sensor (B42).
<- Go to Section TOC
Section 9001 page 70
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523110.06- Speed Sensor 2 Voltage Low 44
The clutch C secondary speed sensor is open or short to ground.
Speed Sensor 2 Voltage Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0312 for ground at pin 12 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0312 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check circuit YEL for ground at pin 12 on harness (W5) side of connector (X72). Is ground present?
Result: YES:Circuit YEL is short to ground inside transmission. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 3 ) Open Circuit Check
Action: Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 17 (circuit 0312) on TCU connector (X71) and pin 12 on harness (W4) side of connector (X72). Is continuity indicated?
<- Go to Section TOC
Section 9001 page 71
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Go to next check. NO:Circuit 0312 is open. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
Action: Remove solenoid access cover from top of transmission. Disconnect turbine speed sensor (B40). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for continuity between pin 12 (circuit YEL) of connector (X72) and pin 2 on clutch C secondary speed sensor (B42) connector. Check for continuity between pin 10 (circuit ORG) of connector (X72) and pin 1 on clutch C secondary speed sensor (B42) connector. Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuits without continuity are open. Repair circuits or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 17 (circuit 0312) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0312 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 12 (circuit YEL) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Replace clutch C secondary speed sensor (B42).
<- Go to Section TOC
Section 9001 page 72
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523110.07- Speed Sensor 2 Speed Mismatch 44
The clutch C secondary speed sensor speed data does not match the other speed sensors measured values.
Speed Sensor 2 Speed Mismatch Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523110.03 or 523110.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523110.03 and/or 523110.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace clutch C secondary speed sensor (B42). <- Go to Section TOC
Section 9001 page 73
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 74
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523110.08- Speed Sensor 2 DIR ROT Unknown 44
The transmission control unit (TCU) does not recognize the rotation direction of the clutch C secondary speed sensor.
Speed Sensor 2 DIR ROT Unknown Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523110.03 or 523110.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523110.03 and/or 523110.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace clutch C secondary speed sensor (B42). <- Go to Section TOC
Section 9001 page 75
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 76
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523110.09- Speed Sensor 2 Speed Unknown 44
The clutch C secondary speed sensor data is unknown at the transmission control unit (TCU).
Speed Sensor 2 Speed Unknown Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523110.03 or 523110.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523110.03 and/or 523110.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace clutch C secondary speed sensor (B42). <- Go to Section TOC
Section 9001 page 77
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 78
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523110.11- Speed Sensor 2 DIR ROT Mismatch 44
The clutch C secondary speed sensor rotation data does not match the other speed sensors measured values.
Speed Sensor 2 DIR ROT Mismatch Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523110.03 or 523110.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523110.03 and/or 523110.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace clutch C secondary speed sensor (B42). <- Go to Section TOC
Section 9001 page 79
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 80
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523115.02- Output Speed Sensor Unknown Input 44
The transmission control unit (TCU) detects an unknown electrical component at the output speed sensor.
Output Speed Sensor Unknown Input Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523115.03 or 523115.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523115.03 and/or 523115.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove output speed sensor cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace output speed sensor (B43). <- Go to Section TOC
Section 9001 page 81
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect sensor to proper connection if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 82
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523115.03- Output Speed Sensor Overvoltage 44
The output speed sensor is short to power.
Output Speed Sensor Overvoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect output speed sensor (B43). See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Ignition ON. Check circuit BRN for voltage at pin 2 of output speed sensor connector (B43). Is voltage present?
Result: YES:Go to next check. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check.
Action: Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0314 for voltage at pin 14 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0314 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Circuit BRN is short to power inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 83
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 18 (circuit 0314) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0314 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 14 (circuit BRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 84
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523115.06- Output Speed Sensor Voltage Low 44
The output speed sensor is open or short to ground.
Output Speed Sensor Voltage Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect output speed sensor (B43). See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Check circuit BRN for ground at pin 2 of output speed sensor connector (B43). Is ground present?
Result: YES:Go to next check. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check.
Action: Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0314 for ground at pin 14 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit BRN is short to ground inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Circuit 0314 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) ( 3 ) Open Circuit Check
Action: Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect output speed sensor (B43). See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Check for continuity between pin 18 (circuit 0314) on TCU connector (X71) and pin 2 (circuit BRN) on output speed sensor (B43) connector. Is continuity indicated? <- Go to Section TOC
Section 9001 page 85
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Go to Harness Check. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 18 (circuit 0314) on TCU connector (X71) and pin 14 on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Circuit BRN is open in inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Circuit 0314 is open in harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 18 (circuit 0314) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0314 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 14 (circuit BRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) See Output Speed Sensor Harness (W7) Wiring Diagram . (Group 9015-10.) NO:Replace output speed sensor (B43).
<- Go to Section TOC
Section 9001 page 86
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523115.07- Output Speed Sensor Speed Mismatch 44
The output speed sensor speed data does not match the other speed sensors measured values.
Output Speed Sensor Speed Mismatch Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523115.03 or 523115.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523115.03 and/or 523115.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove output speed sensor cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace output speed sensor (B43). <- Go to Section TOC
Section 9001 page 87
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect sensor to proper connection if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 88
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523115.08- Output Speed Sensor DIR ROT Unknown 44
The transmission control unit (TCU) does not recognize the rotation direction of the output speed sensor.
Output Speed Sensor DIR ROT Unknown Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523115.03 or 523115.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523115.03 and/or 523115.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove output speed sensor cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace output speed sensor (B43). <- Go to Section TOC
Section 9001 page 89
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect sensor to proper connection if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 90
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523115.09- Output Speed Sensor Speed Unknown 44
The output speed sensor data is unknown at the transmission control unit (TCU).
Output Speed Sensor Speed Unknown Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523115.03 or 523115.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523115.03 and/or 523115.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove output speed sensor cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace output speed sensor (B43). <- Go to Section TOC
Section 9001 page 91
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect sensor to proper connection if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 92
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523115.11- Output Speed Sensor DIR ROT Mismatch 44
The output speed sensor rotation data does not match the other speed sensors measured values.
Output Speed Sensor DIR ROT Mismatch Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523115.03 or 523115.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523115.03 and/or 523115.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove output speed sensor cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace output speed sensor (B43). <- Go to Section TOC
Section 9001 page 93
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect sensor to proper connection if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 94
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523120.02- Unknown Electrical Component at Speed Sensor Input 5 44
The transmission control unit (TCU) detects an unknown electrical component at speed sensor input 5.
Unknown Electrical Component at Speed Sensor Input 5 Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523115.03 or 523115.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523115.03 and/or 523115.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove output speed sensor cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
<- Go to Section TOC
Section 9001 page 95
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Replace output speed sensor (B43). NO:Connect sensor to proper connection if needed. Repair or replace connectors as needed.
<- Go to Section TOC
Section 9001 page 96
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523120.03- Speed Sensor Input 5 Overvoltage 44
Speed sensor input 5 is short to power.
Speed Sensor Input 5 Overvoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0312 for voltage at pin 12 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0312 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 17 (circuit 0312) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0312 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 12 (circuit YEL) on harness (W5) side of connector (X72) and all other pins on connector (X72). <- Go to Section TOC
Section 9001 page 97
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Replace clutch C secondary speed sensor (B42).
<- Go to Section TOC
Section 9001 page 98
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523120.06- Speed Sensor Input 5 Open or Short to Ground 44
Speed sensor input 5 is open or short to ground.
Speed Sensor Input 5 Open or Short to Ground Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0312 for voltage at pin 12 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0312 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 17 (circuit 0312) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0312 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 12 (circuit YEL) on harness (W5) side of connector (X72) and all other pins on connector (X72). <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Replace clutch C secondary speed sensor (B42).
<- Go to Section TOC
Section 9001 page 100
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523125.02- Unknown Electrical Component at Voltage Input 1 44
The transmission control unit (TCU) detects an unknown electrical component at voltage input 1.
Unknown Electrical Component at Voltage Input 1 Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523115.03 or 523115.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523115.03 and/or 523115.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove output speed sensor cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace output speed sensor (B43). <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect sensor to proper connection if needed. Repair or replace connectors as needed.
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523130.02- Unknown Electrical Component at Voltage Input 2 44
The transmission control unit (TCU) detects an unknown electrical component at voltage input 2.
Unknown Electrical Component at Voltage Input 2 Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523115.03 or 523115.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523115.03 and/or 523115.06 and recheck diagnostic trouble codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove output speed sensor cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace output speed sensor (B43). <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect sensor to proper connection if needed. Repair or replace connectors as needed.
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523140.02- Sump Temp Input Unknown Input 44
The transmission control unit (TCU) detects an unknown component at the transmission sump temperature sensor input.
Sump Temp Input Unknown Input Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect transmission sump temperature sensor (B39). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of transmission sump temperature sensor (B39). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification? <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace transmission sump temperature sensor (B39).
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523140.03- Sump Temp Sensor Voltage High 44
The transmission sump temperature sensor is open or short to power.
Sump Temp Sensor Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove solenoid access cover on transmission. Disconnect transmission sump temperature sensor (B39). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of transmission sump temperature sensor (B39). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace transmission sump temperature sensor (B39). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission sump temperature sensor (B39). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Ignition ON. Check circuit YEL for voltage at pin 1 of transmission sump temperature sensor (B39) connector. Is voltage present?
Result: YES:Circuit YEL is short to power. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 4 ) Open Circuit Check
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Action: Ignition OFF. Disconnect transmission sump temperature sensor (B39). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit YEL) of transmission sump temperature sensor (B39) and pin 27 (circuit 0308) on TCU connector (X71). Check for continuity between pin 2 (circuit BLU) of transmission sump temperature sensor (B39) and pin 32 (circuit 0321) on TCU connector (X71). Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuits without continuity are open. Repair circuits or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) ( 5 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 27 (circuit 0308) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0308 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 8 (circuit YEL) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 108
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523140.05- Sump Temp Sensor Overvoltage 44
The transmission sump temperature sensor is open.
Sump Temp Sensor Overvoltage Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove solenoid access cover on transmission. Disconnect transmission sump temperature sensor (B39). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of transmission sump temperature sensor (B39). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Open Circuit. NO:Replace transmission sump temperature sensor (B39). ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect transmission sump temperature sensor (B39). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit YEL) of transmission sump temperature sensor (B39) and pin 27 (circuit 0308) on TCU connector (X71). Check for continuity between pin 2 (circuit BLU) of transmission sump temperature sensor (B39) and pin 32 (circuit 0321) on TCU connector (X71). Is continuity indicated?
Result: YES:Program transmission control unit (TCU). NO:Circuits without continuity are open. Repair circuits or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 109
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<- Go to Section TOC
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Section 9001 page 110
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523140.06- Sump Temp Sensor Voltage Low 44
The transmission sump temperature sensor short to ground.
Sump Temp Sensor Voltage Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove solenoid access cover on transmission. Disconnect transmission sump temperature sensor (B39). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of transmission sump temperature sensor (B39). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace transmission sump temperature sensor (B39). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission sump temperature sensor (B39). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check circuit YEL for ground at pin 1 of transmission sump temperature sensor connector. Is ground present?
Result: YES:Circuit YEL is short to ground. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 27 (circuit 0308) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0308 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 8 (circuit YEL) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 112
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523145.02- Torq/RTDR Temp Snsr Unknown Input 44
The transmission control unit (TCU) detects an unknown component at the retarder temperature sensor input.
Torq/RTDR Temp Snsr Unknown Input Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect retarder temperature sensor (B38). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of retarder temperature sensor (B38). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
<- Go to Section TOC
Section 9001 page 113
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace retarder temperature sensor (B38).
<- Go to Section TOC
Section 9001 page 114
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523145.03- Torq/RTDR Temp Snsr Unknown Voltage High 44
The retarder temperature sensor is open or short to power.
Torq/RTDR Temp Snsr Unknown Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove retarder temperature sensor access plug on transmission. Disconnect retarder temperature sensor (B38). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of retarder temperature sensor (B38). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace retarder temperature sensor (B38). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect retarder temperature sensor (B38). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Ignition ON. Check circuit ORG for voltage at pin 1 of retarder temperature sensor (B38) connector. Is voltage present?
Result: YES:Circuit 0322 and/or ORG is short to power. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 4 ) Open Circuit Check
Action: Ignition OFF. Disconnect retarder temperature sensor (B38). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 115
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Disconnect transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit ORG) of retarder temperature sensor (B38) and pin 21 (circuit 0322) on TCU connector (X71). Check for continuity between pin 2 (circuit BLU) of retarder temperature sensor (B38) and pin 28 (circuit 0309) on TCU connector (X71). Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuits that do not indicate continuity are open. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) ( 5 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 21 (circuit 0322) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0322 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 22 (circuit ORG) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 116
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523145.05- Torq/RTDR Temp Snsr Overvoltage 44
The retarder temperature sensor is open.
Torq/RTDR Temp Snsr Overvoltage Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove solenoid access cover on transmission. Disconnect retarder temperature sensor (B38). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of retarder temperature sensor (B38). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Open Circuit Check. NO:Replace retarder temperature sensor (B38). ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect retarder temperature sensor (B38). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit ORG) of retarder temperature sensor (B38) and pin 28 (circuit 0309) on TCU connector (X71). Check for continuity between pin 2 (circuit BLU) of retarder temperature sensor (B38) and pin 21 (circuit 0322) on TCU connector (X71). Is continuity indicated?
Result: YES:Program transmission control unit (TCU). NO:Circuits that do not indicate continuity are open. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 117
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523145.06- Torq/RTDR Temp Snsr Ground Low 44
The retarder temperature sensor is short to ground.
Torq/RTDR Temp Snsr Ground Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove retarder temperature sensor access plug on transmission. Disconnect retarder temperature sensor (B38). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of retarder temperature sensor (B38). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace retarder temperature sensor (B38). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect retarder temperature sensor (B38). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Ignition ON. Check circuit ORG for ground at pin 1 of retarder temperature sensor (B38) connector. Is ground present?
Result: YES:Circuit ORG is short to ground. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
(Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 21 (circuit 0322) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0322 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 9 (circuit ORG) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-40.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 119
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523150.02- Unknown Electrical Component at Current Input 1 44
The transmission control unit (TCU) detects an unknown component at the retarder temperature sensor input.
Unknown Electrical Component at Current Input 1 Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect retarder temperature sensor (B38). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of retarder temperature sensor (B38). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace retarder temperature sensor (B38).
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523155.02- Unknown Electrical Component at Current Input 2 44
The transmission control unit (TCU) detects an unknown component at the retarder temperature sensor input.
Unknown Electrical Component at Current Input 2 Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect retarder temperature sensor (B38). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of retarder temperature sensor (B38). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace retarder temperature sensor (B38).
<- Go to Section TOC
Section 9001 page 123
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523155.03- Oil Filt Rest Switch Overvoltage 44
The oil filter restriction switch is short to power.
Oil Filt Rest Switch Overvoltage Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of transmission filter restriction switch (B17). Are approximately 510 ohms present?
Result: YES:Go to Short Circuit Check. NO:Program transmission filter restriction switch (B17). ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit N13 YEL for voltage at pin 2 of transmission filter restriction switch (B17) connector. Are 6.3 volts or more present?
Result: YES:Circuit N13 YEL is short to power. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 25 (circuit 0202) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit 0202 and/or N13 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
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Section 9001 page 125
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523155.04- Oil Filt Rest Switch Undervoltage 44
The oil filter restriction switch is short to ground.
Oil Filt Rest Switch Undervoltage Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of transmission filter restriction switch (B17). Are approximately 510 ohms present?
Result: YES:Go to Short Circuit Check. NO:Replace transmission filter restriction switch (B17). ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check circuit N13 YEL for ground at pin 2 of transmission filter restriction switch (B17) connector. Is ground present?
Result: YES:Circuit 0202 and/or N13 YEL is short to ground. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 25 (circuit 0202) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated? <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Circuit 0202 and/or N13 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523155.06- Oil Filt Rest Switch Voltage Low 44
The oil filter restriction switch is open or short to ground.
Oil Filt Rest Switch Voltage Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of transmission filter restriction switch (B17). Are approximately 510 ohms present?
Result: YES:Go to Short Circuit Check. NO:Replace transmission filter restriction switch (B17). ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit 0202 for ground at pin 2 of transmission filter restriction switch (B17) connector. Is ground present?
Result: YES:Circuit 0202 and/or N13 YEL is short to ground. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 4 ) Open Circuit Check
Action: Ignition OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Check for continuity between pin 2 (circuit N13 YEL) of transmission filter restriction switch (B17) and pin 25 (circuit 0202) on TCU connector (X71). Is continuity indicated?
Result: YES:Circuit 0202 and/or N13 YEL is open. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 5 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 25 (circuit 0202) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0202 and/or N13 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
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Section 9001 page 129
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523200.00- Clutch A Slip Unintentional Slip 44
The transmission control unit (TCU) detects that clutch A is slipping.
Clutch A Slip Unintentional Slip Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active speed sensor codes, transmission filter restriction codes, or transmission control unit (TCU) DTCs present?
Result: YES:Correct all active speed sensor codes, transmission filter restriction codes, and TCU codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 5 ) Component Check
Action: Disconnect clutch A solenoid (Y60). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y60). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to System Pressure Check. NO:Replace clutch A solenoid (Y60). ( 6 ) System Pressure Check
Action: Check transmission system pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Go to Clutch Pressure Check. NO:Diagnose and repair transmission pump. See Transmission Disassemble . (Group 0350.) ( 7 ) Clutch Pressure Check
Action: Check clutch A pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Program transmission control unit (TCU). NO:Diagnose and repair transmission clutch A. See Transmission Disassemble . (Group 0350.)
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Section 9001 page 131
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523200.02- Current Output 1 Unknown ELC Comp 44
The transmission control unit (TCU) detects an unknown component at clutch A solenoid input.
Current Output 1 Unknown ELC Comp Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect clutch A solenoid (Y60). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch A solenoid (Y60). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
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Section 9001 page 132
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace clutch A solenoid (Y60).
<- Go to Section TOC
Section 9001 page 133
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523200.03- Clutch A Propvalve Voltage High 44
The clutch A solenoid is short to power.
Clutch A Propvalve Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch A solenoid (Y60). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y60). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch A solenoid (Y60). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0301 for voltage at pin 1 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0301 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
Section 9001 page 134
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 13 (circuit 0301) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0301 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 1 (circuit BLU) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BLU is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
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Section 9001 page 135
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523200.05- Clutch A Propvalve Current Low 44
The clutch A solenoid is open.
Clutch A Propvalve Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch A solenoid (Y60). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch A solenoid (Y60). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Open Circuit Check. NO:Replace clutch A solenoid (Y60). ( 3 ) Open Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0301 for continuity between pin 13 of connector (X71) and pin 1 on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit 0301 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
Action: Disconnect clutch A solenoid (Y60). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check circuit BLU for continuity between pin 1 on harness (W5) side of connector (X72) and pin 1 on clutch A solenoid (Y60) <- Go to Section TOC
Section 9001 page 136
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
harness connector. Check circuit RED for continuity between pin 23 on harness (W5) side of connector (X72) and pin 2 on clutch A solenoid (Y60) harness connector. Is continuity indicated?
Result: YES:Program transmission control unit (TCU). NO:Circuits that do not indicate continuity are open in clutch control harness (W5). Repair circuits or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 137
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523200.06- Clutch A Propvalve Ground Low 44
The clutch A solenoid is short to ground.
Clutch A Propvalve Ground Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch A solenoid (Y60). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch A solenoid (Y60). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch A solenoid (Y60). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0301 for ground at pin 1 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0301 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check circuit BLU for ground at pin 1 on harness (W5) side of connector (X72). Is ground present?
Result: YES:Circuit BLU is short to ground inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 13 (circuit 0301) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0301 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 1 (circuit BLU) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BLU is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523200.08- Clutch A Propvalve Short to ALT Valve 44
The transmission control unit (TCU) detects clutch A solenoid input is short to another solenoid.
Clutch A Propvalve Short to ALT Valve Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Component Check. NO:Repair or replace connectors. ( 3 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch A solenoid (Y60). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch A solenoid (Y60). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Harness Check. NO:Replace clutch A solenoid (Y60). ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Check for continuity between pin 13 (circuit 0301) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0301 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 1 (circuit BLU) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BLU is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 141
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523205.00- Clutch B Slip Unintentional Slip 44
The transmission control unit (TCU) detects that clutch B is slipping.
Clutch B Slip Unintentional Slip Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active speed sensor codes, transmission filter restriction codes, or transmission control unit (TCU) DTCs present?
Result: YES:Correct all active speed sensor codes, transmission filter restriction, and TCU codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 5 ) Component Check
Action: Disconnect clutch B solenoid (Y61). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y61). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to System Pressure Check. NO:Replace clutch B solenoid (Y61). ( 6 ) System Pressure Check
Action: Check transmission system pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Go to Clutch Pressure Check. NO:Diagnose and repair transmission pump. See Transmission Disassemble . (Group 0350.) ( 7 ) Clutch Pressure Check
Action: Check clutch B pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Program transmission control unit (TCU). NO:Diagnose and repair transmission clutch B. See Transmission Disassemble . (Group 0350.)
<- Go to Section TOC
Section 9001 page 143
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523205.02- Current Output 2 Unknown ELC Comp 44
The transmission control unit (TCU) detects an unknown component at clutch B solenoid input.
Current Output 2 Unknown ELC Comp Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect clutch B solenoid (Y61). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch B solenoid (Y61). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
<- Go to Section TOC
Section 9001 page 144
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace clutch B solenoid (Y61).
<- Go to Section TOC
Section 9001 page 145
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523205.03- Clutch B Propvalve Voltage High 44
The clutch B solenoid is short to power.
Clutch B Propvalve Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch B solenoid (Y61). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y61). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch B solenoid (Y61). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0302 for voltage at pin 2 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0302 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
Section 9001 page 146
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 3 (circuit 0302) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0302 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 2 (circuit YEL) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 147
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523205.05- Clutch B Propvalve Current Low 44
The clutch B solenoid is open.
Clutch B Propvalve Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch B solenoid (Y61). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch B solenoid (Y61). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Open Circuit Check. NO:Replace clutch B solenoid (Y61). ( 3 ) Open Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0302 for continuity between pin 3 of connector (X71) and pin 2 on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit 0302 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
Action: Disconnect clutch B solenoid (Y61). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check circuit YEL for continuity between pin 2 on harness (W5) side of connector (X72) and pin 1 on clutch B solenoid (Y61) <- Go to Section TOC
Section 9001 page 148
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
harness connector. Check circuit RED for continuity between pin 23 on harness (W5) side of connector (X72) and pin 2 on clutch B solenoid (Y61) harness connector. Is continuity indicated?
Result: YES:Program transmission control unit (TCU). NO:Circuits that do not indicate continuity are open in transmission control harness (W4). Repair circuits or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 149
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523205.06- Clutch B Propvalve Ground Low 44
The clutch B solenoid is short to ground.
Clutch B Propvalve Ground Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch B solenoid (Y61). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch B solenoid (Y61). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch B solenoid (Y61). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0302 for ground at pin 2 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0302 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check circuit YEL for ground at pin 2 on harness (W5) side of connector (X72). Is ground present?
Result: YES:Circuit YEL is short to ground inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 150
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 3 (circuit 0302) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0302 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 2 (circuit YEL) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 151
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523205.08- Clutch B Propvalve Short to ALT Valve 44
The transmission control unit (TCU) detects clutch B solenoid input is short to another solenoid.
Clutch B Propvalve Short to ALT Valve Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Component Check. NO:Repair or replace connectors. ( 3 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch B solenoid (Y61). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch B solenoid (Y61). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Harness Check. NO:Replace clutch B solenoid (Y61). ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 152
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Check for continuity between pin 3 (circuit 0302) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0302 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 2 (circuit YEL) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 153
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523210.00- Clutch C Slip Unintentional Slip 44
The transmission control unit (TCU) detects that clutch C is slipping.
Clutch C Slip Unintentional Slip Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active speed sensor codes, transmission filter restriction codes, or transmission control unit (TCU) DTCs present?
Result: YES:Correct all active speed sensor codes, transmission filter restriction codes, and TCU codes. NO:Go to Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. <- Go to Section TOC
Section 9001 page 154
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 5 ) Component Check
Action: Disconnect clutch C solenoid (Y62). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y62). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to System Pressure Check. NO:Replace clutch C solenoid (Y62). ( 6 ) System Pressure Check
Action: Check transmission system pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Go to Clutch Pressure Check. NO:Diagnose and repair transmission pump. See Transmission Disassemble . (Group 0350.) ( 7 ) Clutch Pressure Check
Action: Check clutch C pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Program transmission control unit (TCU). NO:Diagnose and repair transmission clutch C. See Transmission Disassemble . (Group 0350.)
<- Go to Section TOC
Section 9001 page 155
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523210.02- Current Output 3 Unknown ELC Comp 44
The transmission control unit (TCU) detects an unknown component at clutch C solenoid input.
Current Output 3 Unknown ELC Comp Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect clutch C solenoid (Y62). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch C solenoid (Y62). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
<- Go to Section TOC
Section 9001 page 156
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace clutch C solenoid (Y62).
<- Go to Section TOC
Section 9001 page 157
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523210.03- Clutch C Propvalve Voltage High 44
The clutch C solenoid is short to power.
Clutch C Propvalve Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch C solenoid (Y62). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y62). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch C solenoid (Y62). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0303 for voltage at pin 3 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0303 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
Section 9001 page 158
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 4 (circuit 0303) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0303 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 3 (circuit BRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 159
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523210.05- Clutch C Propvalve Current Low 44
The clutch C solenoid is open.
Clutch C Propvalve Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch C solenoid (Y62). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch C solenoid (Y62). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Open Circuit Check. NO:Replace clutch C solenoid (Y62). ( 3 ) Open Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0303 for continuity between pin 4 of connector (X71) and pin 3 on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit 0303 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
Action: Disconnect clutch C solenoid (Y62). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check circuit BRN for continuity between pin 3 on harness (W5) side of connector (X72) and pin 1 on clutch C solenoid (Y62) <- Go to Section TOC
Section 9001 page 160
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
harness connector. Check circuit RED for continuity between pin 23 on harness (W5) side of connector (X72) and pin 2 on clutch C solenoid (Y62) harness connector. Is continuity indicated?
Result: YES:Program transmission control unit (TCU). NO:Circuit that does not indicate continuity is open in transmission control harness (W4). Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 161
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523210.06- Clutch C Propvalve Ground Low 44
The clutch C solenoid is short to ground.
Clutch C Propvalve Ground Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch C solenoid (Y62). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch C solenoid (Y62). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch C solenoid (Y62). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0303 for ground at pin 3 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0303 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check circuit BRN for ground at pin 3 on harness (W5) side of connector (X72). Is ground present?
Result: YES:Circuit BRN is short to ground inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 4 (circuit 0303) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0303 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 3 (circuit BRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 163
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523210.08- Clutch C Propvalve Short to ALT Valve 44
The transmission control unit (TCU) detects clutch C solenoid input is short to another solenoid.
Clutch C Propvalve Short to ALT Valve Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Component Check. NO:Repair or replace connectors. ( 3 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch C solenoid (Y62). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch C solenoid (Y62). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Harness Check. NO:Replace clutch C solenoid (Y62). ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 164
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Check for continuity between pin 4 (circuit 0303) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0303 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 3 (circuit BRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 165
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523215.00- Clutch D Slip Unintentional Slip 44
The transmission control unit (TCU) detects that clutch D is slipping.
Clutch D Slip Unintentional Slip Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active speed sensor codes, transmission filter restriction codes, or transmission control unit (TCU) DTCs present?
Result: YES:Correct all active speed sensor codes, transmission filter restriction codes, and TCU codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. <- Go to Section TOC
Section 9001 page 166
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 5 ) Component Check
Action: Disconnect clutch D solenoid (Y63). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y63). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to System Pressure Check. NO:Replace clutch D solenoid (Y63). ( 6 ) System Pressure Check
Action: Check transmission system pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Go to Clutch Pressure Check. NO:Diagnose and repair transmission pump. See Transmission Disassemble . (Group 0350.) ( 7 ) Clutch Pressure Check
Action: Check clutch D pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Program transmission control unit (TCU). NO:Diagnose and repair transmission clutch D. See Transmission Disassemble . (Group 0350.)
<- Go to Section TOC
Section 9001 page 167
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523215.02- Current Output 4 Unknown ELC Comp 44
The transmission control unit (TCU) detects an unknown component at clutch D solenoid input.
Current Output 4 Unknown ELC Comp Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect clutch D solenoid (Y63). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch D solenoid (Y63). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
<- Go to Section TOC
Section 9001 page 168
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace clutch D solenoid (Y63).
<- Go to Section TOC
Section 9001 page 169
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523215.03- Clutch D Propvalve Voltage High 44
The clutch D solenoid is short to power.
Clutch D Propvalve Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch D solenoid (Y63). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y63). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch D solenoid (Y63). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0304 for voltage at pin 4 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0304 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
Section 9001 page 170
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 6 (circuit 0304) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0304 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 4 (circuit WHT) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 171
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523215.05- Clutch D Propvalve Current Low 44
The clutch D solenoid is open.
Clutch D Propvalve Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch D solenoid (Y63). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch D solenoid (Y63). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Open Circuit Check. NO:Replace clutch D solenoid (Y63). ( 3 ) Open Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0304 for continuity between pin 6 of connector (X71) and pin 4 on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit 0304 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
Action: Disconnect clutch D solenoid (Y63). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check circuit WHT for continuity between pin 4 on harness (W5) side of connector (X72) and pin 1 on clutch D solenoid (Y63) <- Go to Section TOC
Section 9001 page 172
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
harness connector. Check circuit RED for continuity between pin 23 on harness (W5) side of connector (X72) and pin 2 on clutch D solenoid (Y63) harness connector. Is continuity indicated?
Result: YES:Program transmission control unit (TCU). NO:Circuit that does not indicate continuity is open in transmission control harness (W4). Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 173
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523215.06- Clutch D Propvalve Ground Low 44
The clutch D solenoid is short to ground.
Clutch D Propvalve Ground Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch D solenoid (Y63). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch D solenoid (Y63). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch D solenoid (Y63). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0304 for ground at pin 4 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0304 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check circuit WHT for ground at pin 4 on harness (W5) side of connector (X72). Is ground present?
Result: YES:Circuit WHT is short to ground inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 174
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 6 (circuit 0304) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0304 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 4 (circuit WHT) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 175
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523215.08- Clutch D Propvalve Short to ALT Valve 44
The transmission control unit (TCU) detects clutch D solenoid input is short to another solenoid.
Clutch D Propvalve Short to ALT Valve Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Component Check. NO:Repair or replace connectors. ( 3 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch D solenoid (Y63). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch D solenoid (Y63). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Harness Check. NO:Replace clutch D solenoid (Y63). ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 176
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Check for continuity between pin 6 (circuit 0304) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0304 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 4 (circuit WHT) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 177
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523220.00- Clutch R Slip Unintentional Slip 44
The transmission control unit (TCU) detects that clutch R is slipping.
Clutch R Slip Unintentional Slip Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active speed sensor codes, transmission filter restriction codes, or transmission control unit (TCU) DTCs present?
Result: YES:Correct all active speed sensor codes, transmission filter restriction codes, and TCU codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. <- Go to Section TOC
Section 9001 page 178
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 5 ) Component Check
Action: Disconnect clutch R solenoid (Y66). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y66). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to System Pressure Check. NO:Replace clutch R solenoid (Y66). ( 6 ) System Pressure Check
Action: Check transmission system pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Go to Clutch Pressure Check. NO:Diagnose and repair transmission pump. See Transmission Disassemble . (Group 0350.) ( 7 ) Clutch Pressure Check
Action: Check clutch R pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Program transmission control unit (TCU). NO:Diagnose and repair transmission clutch R. See Transmission Disassemble . (Group 0350.)
<- Go to Section TOC
Section 9001 page 179
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523220.02- Current Output 5 Unknown ELC Comp 44
The transmission control unit (TCU) detects an unknown component at clutch R solenoid input.
Current Output 5 Unknown ELC Comp Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect clutch R solenoid (Y66). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch R solenoid (Y66). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
<- Go to Section TOC
Section 9001 page 180
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace clutch R solenoid (Y66).
<- Go to Section TOC
Section 9001 page 181
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523220.03- Clutch R Propvalve Voltage High 44
The clutch R solenoid is short to power.
Clutch R Propvalve Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch R solenoid (Y66). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y66). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch R solenoid (Y66). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0305 for voltage at pin 5 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0305 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
Section 9001 page 182
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 7 (circuit 0305) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0305 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 5 (circuit GRY) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit GRY is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 183
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523220.05- Clutch R Propvalve Current Low 44
The clutch R solenoid is open.
Clutch R Propvalve Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch R solenoid (Y66). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch R solenoid (Y66). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Open Circuit Check. NO:Replace clutch R solenoid (Y66). ( 3 ) Open Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0305 for continuity between pin 7 of connector (X71) and pin 5 on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit 0305 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
Action: Disconnect clutch R solenoid (Y66). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check circuit GRY for continuity between pin 5 on harness (W5) side of connector (X72) and pin 1 on clutch R solenoid (Y66) <- Go to Section TOC
Section 9001 page 184
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
harness connector. Check circuit RED for continuity between pin 23 on harness (W5) side of connector (X72) and pin 2 on clutch R solenoid (Y66) harness connector. Is continuity indicated?
Result: YES:Program transmission control unit (TCU). NO:Circuit that does not indicate continuity is open in transmission control harness (W5). Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 185
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523220.06- Clutch R Propvalve Ground Low 44
The clutch R solenoid is short to ground.
Clutch R Propvalve Ground Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch R solenoid (Y66). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch R solenoid (Y66). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch R solenoid (Y66). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0305 for ground at pin 5 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0305 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check circuit GRY for ground at pin 5 on harness (W5) side of connector (X72). Is ground present?
Result: YES:Circuit GRY is short to ground inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 186
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 7 (circuit 0305) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0305 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 5 (circuit GRY) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit GRY is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 187
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523220.08- Clutch R Propvalve Short to ALT Valve 44
The transmission control unit (TCU) detects clutch R solenoid input is short to another solenoid.
Clutch R Propvalve Short to ALT Valve Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Component Check. NO:Repair or replace connectors. ( 3 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch R solenoid (Y66). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch R solenoid (Y66). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Harness Check. NO:Replace clutch R solenoid (Y66). ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 188
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Check for continuity between pin 7 (circuit 0305) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0305 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 5 (circuit GRY) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit GRY is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 189
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523225.00- Clutch F Slip Unintentional Slip 44
The transmission control unit (TCU) detects that clutch F is slipping.
Clutch F Slip Unintentional Slip Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active speed sensor codes, transmission filter restriction codes, or transmission control unit (TCU) DTCs present?
Result: YES:Correct all active speed sensor codes, transmission filter restriction codes, and TCU codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. <- Go to Section TOC
Section 9001 page 190
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 5 ) Component Check
Action: Disconnect clutch F solenoid (Y65). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y65). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to System Pressure Check. NO:Replace clutch F solenoid (Y65). ( 6 ) System Pressure Check
Action: Check transmission system pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Go to Clutch Pressure Check. NO:Diagnose and repair transmission pump. See Transmission Disassemble . (Group 0350.) ( 7 ) Clutch Pressure Check
Action: Check clutch F pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Program transmission control unit (TCU). NO:Diagnose and repair transmission clutch F. See Transmission Disassemble . (Group 0350.)
<- Go to Section TOC
Section 9001 page 191
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523225.02- Current Output 6 Unknown ELC Comp 44
The transmission control unit (TCU) detects an unknown component at clutch F solenoid input.
Current Output 6 Unknown ELC Comp Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect clutch F solenoid (Y65). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch F solenoid (Y65). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
<- Go to Section TOC
Section 9001 page 192
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace clutch F solenoid (Y65).
<- Go to Section TOC
Section 9001 page 193
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523225.03- Clutch F Propvalve Voltage High 44
The clutch F solenoid is short to power.
Clutch F Propvalve Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch F solenoid (Y65). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y65). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch F solenoid (Y65). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0306 for voltage at pin 6 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0306 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
Section 9001 page 194
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 8 (circuit 0306) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0306 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 6 (circuit GRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 195
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523225.05- Cutch F Propvalve Current Low 44
The clutch F solenoid is open.
Cutch F Propvalve Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch F solenoid (Y65). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch F solenoid (Y65). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Open Circuit Check. NO:Replace clutch F solenoid (Y65). ( 3 ) Open Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0306 for continuity between pin 6 of connector (X71) and pin 4 on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit 0306 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
Action: Disconnect clutch F solenoid (Y65). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check circuit GRN for continuity between pin 4 on harness (W5) side of connector (X72) and pin 1 on clutch F solenoid (Y65) <- Go to Section TOC
Section 9001 page 196
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
harness connector. Check circuit RED for continuity between pin 23 on harness (W5) side of connector (X72) and pin 2 on clutch F solenoid (Y65) harness connector. Is continuity indicated?
Result: YES:Program transmission control unit (TCU). NO:Circuit that does not indicate continuity is open in transmission control harness (W5). Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 197
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523225.06- Clutch F Propvalve Voltage Low 44
The clutch F solenoid is short to ground.
Clutch F Propvalve Voltage Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch F solenoid (Y65). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch R solenoid (Y65). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch F solenoid (Y65). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0306 for ground at pin 6 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0306 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
Section 9001 page 198
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 8 (circuit 0306) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0306 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 6 (circuit GRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 199
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523225.08- Clutch F Propvalve Short to ALT Valve 44
The transmission control unit (TCU) detects clutch F solenoid input is short to another solenoid.
Clutch F Propvalve Short to ALT Valve Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Component Check. NO:Repair or replace connectors. ( 3 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch F solenoid (Y65). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch F solenoid (Y65). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Harness Check. NO:Replace clutch F solenoid (Y65). ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 200
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Check for continuity between pin 8 (circuit 0306) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0306 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 6 (circuit GRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 201
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523230.00- Clutch V Slip Unintentional Slip 44
The transmission control unit (TCU) detects that clutch V is slipping.
Clutch V Slip Unintentional Slip Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active speed sensor codes, transmission filter restriction codes, or transmission control unit (TCU) DTCs present?
Result: YES:Correct all active speed sensor codes, transmission filter restriction codes, and TCU codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location and see Retarder Control Harness (W6) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. <- Go to Section TOC
Section 9001 page 202
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 5 ) Component Check
Action: Disconnect clutch V solenoid (Y67). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y67). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to System Pressure Check. NO:Replace clutch V solenoid (Y67). ( 6 ) System Pressure Check
Action: Check transmission system pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Go to Clutch Pressure Check. NO:Diagnose and repair transmission pump. See Transmission Disassemble . (Group 0350.) ( 7 ) Clutch Pressure Check
Action: Check clutch V pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Program transmission control unit (TCU). NO:Diagnose and repair transmission clutch V. See Transmission Disassemble . (Group 0350.)
<- Go to Section TOC
Section 9001 page 203
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523230.02- Current Output 7 Unknown ELC Comp 44
The transmission control unit (TCU) detects an unknown component at clutch V solenoid input.
Current Output 7 Unknown ELC Comp Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location and see Retarder Control Harness (W6) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect clutch V solenoid (Y67). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch V solenoid (Y67). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
<- Go to Section TOC
Section 9001 page 204
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace clutch V solenoid (Y67).
<- Go to Section TOC
Section 9001 page 205
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523230.03- Clutch V Propvalve Voltage High 44
The clutch V solenoid is short to power.
Clutch V Propvalve Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch V solenoid (Y67). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y67). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch V solenoid (Y67). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0307 for voltage at pin 7 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0307 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
Section 9001 page 206
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 10 (circuit 0307) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0307 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 7 (circuit GRY) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit GRY is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
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Section 9001 page 207
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523230.05- Clutch V Propvalve Current Low 44
The clutch V solenoid is open.
Clutch V Propvalve Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch V solenoid (Y67). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch V solenoid (Y67). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Open Circuit Check. NO:Replace clutch V solenoid (Y67). ( 3 ) Open Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0307 for continuity between pin 10 of connector (X71) and pin 7 on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit 0307 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
Action: Disconnect clutch V solenoid (Y67). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check circuit GRY for continuity between pin 7 on harness (W5) side of connector (X72) and pin 1 on clutch V solenoid (Y67) <- Go to Section TOC
Section 9001 page 208
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
harness connector. Check circuit RED for continuity between pin 7 on harness (W5) side of connector (X72) and pin 2 on clutch V solenoid (Y67) harness connector. Is continuity indicated?
Result: YES:Program transmission control unit (TCU). NO:Circuits that do not indicate continuity are open in transmission control harness (W5). Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 209
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523230.06- Clutch V Propvalve Ground Low 44
The clutch V solenoid is short to ground.
Clutch V Propvalve Ground Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch V solenoid (Y67). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch V solenoid (Y67). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch V solenoid (Y67). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0307 for ground at pin 7 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0307 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check circuit GRY for ground at pin 7 on harness (W5) side of connector (X72). Is ground present?
Result: YES:Circuit GRY is short to ground inside transmission. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 210
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 10 (circuit 0307) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0307 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 7 (circuit GRY) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit GRY is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
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Section 9001 page 211
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523230.08- Clutch V Propvalve Short to ALT Valve 44
The transmission control unit (TCU) detects clutch V solenoid input is short to another solenoid.
Clutch V Propvalve Short to ALT Valve Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Component Check. NO:Repair or replace connectors. ( 3 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch V solenoid (Y67). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch V solenoid (Y67). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Harness Check. NO:Replace clutch V solenoid (Y67). ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 212
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Check for continuity between pin 10 (circuit 0307) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0307 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 7 (circuit GRY) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit GRY is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
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Section 9001 page 213
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523235.00- Clutch E Slip Unintentional Slip 44
The transmission control unit (TCU) detects that clutch E is slipping.
Clutch E Slip Unintentional Slip Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active speed sensor codes, transmission filter restriction codes, or transmission control unit (TCU) DTCs present?
Result: YES:Correct all active speed sensor codes, transmission filter restriction codes, and TCU codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location and see Retarder Control Harness (W6) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. <- Go to Section TOC
Section 9001 page 214
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 5 ) Component Check
Action: Disconnect clutch E solenoid (Y64). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y64). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to System Pressure Check. NO:Replace clutch E solenoid (Y64). ( 6 ) System Pressure Check
Action: Check transmission system pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Go to Clutch Pressure Check. NO:Diagnose and repair transmission pump. See Transmission Disassemble . (Group 0350.) ( 7 ) Clutch Pressure Check
Action: Check clutch E pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Program transmission control unit (TCU). NO:Diagnose and repair transmission clutch E. See Transmission Disassemble . (Group 0350.)
<- Go to Section TOC
Section 9001 page 215
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523235.02- Current Output 8 Unknown ELC Comp 44
The transmission control unit (TCU) detects an unknown component at clutch E solenoid input.
Current Output 8 Unknown ELC Comp Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location and see Retarder Control Harness (W6) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect clutch E solenoid (Y64). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch E solenoid (Y64). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
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Section 9001 page 216
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace clutch E solenoid (Y64).
<- Go to Section TOC
Section 9001 page 217
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523235.03- Clutch E Propvalve Voltage High 44
The clutch E solenoid is short to power.
Clutch E Propvalve Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch E solenoid (Y64). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y64). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch E solenoid (Y64). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0319 for voltage at pin 19 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0319 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
Section 9001 page 218
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 11 (circuit 0319) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0319 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 19 (circuit WHT) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 219
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523235.05- Cutch E Propvalve Current Low 44
The clutch E solenoid is open.
Cutch E Propvalve Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch E solenoid (Y64). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch E solenoid (Y64). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Open Circuit Check. NO:Replace clutch E solenoid (Y64). ( 3 ) Open Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0319 for continuity between pin 11 of connector (X71) and pin 19 on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit 0319 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
Action: Disconnect clutch E solenoid (Y64). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check circuit WHT for continuity between pin 19 on harness (W5) side of connector (X72) and pin 1 on clutch E solenoid (Y64) <- Go to Section TOC
Section 9001 page 220
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
harness connector. Check circuit RED for continuity between pin 23 on harness (W5) side of connector (X72) and pin 2 on clutch E solenoid (Y64) harness connector. Is continuity indicated?
Result: YES:Program transmission control unit (TCU). NO:Circuits that do not indicate continuity are open in transmission control harness (W5). Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 221
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523235.06- Clutch E Propvalve Voltage Low 44
The clutch E solenoid is short to ground.
Clutch E Propvalve Voltage Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect clutch E solenoid (Y64). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch V solenoid (Y64). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace clutch E solenoid (Y64). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0319 for ground at pin 19 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0319 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
Section 9001 page 222
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 11 (circuit 0319) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0319 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 19 (circuit WHT) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 223
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523235.08- Clutch E Propvalve Short to ALT Valve 44
The transmission control unit (TCU) detects clutch E solenoid input is short to another solenoid.
Clutch E Propvalve Short to ALT Valve Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Component Check. NO:Repair or replace connectors. ( 3 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect clutch E solenoid (Y64). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of clutch E solenoid (Y64). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Harness Check. NO:Replace clutch E solenoid (Y64). ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 224
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Check for continuity between pin 11 (circuit 0319) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0319 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 19 (circuit WHT) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 225
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523240.00- TORQ CVTR Slip Unintentional Slip 44
The transmission control unit (TCU) detects that the torque converter lockup clutch is slipping.
TORQ CVTR Slip Unintentional Slip Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active speed sensor codes, transmission filter restriction codes, or transmission control unit (TCU) DTCs present?
Result: YES:Correct all active speed sensor codes, transmission filter restriction codes, and TCU codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 4 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location and see Retarder Control Harness (W6) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 5 ) Component Check
Action: Disconnect torque converter lockup (WK) solenoid (Y68). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y68). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to System Pressure Check. NO:Replace torque converter lockup (WK) solenoid (Y68). ( 6 ) System Pressure Check
Action: Check transmission system pressure. See Transmission Pressure Test . (Group 9020-25.) Is pressure within specification?
Result: YES:Program transmission control unit (TCU). NO:Diagnose and repair transmission pump. See Transmission Disassemble . (Group 0350.)
<- Go to Section TOC
Section 9001 page 227
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523240.02- Current Output 9 Unknown ELC Comp 44
The transmission control unit (TCU) detects an unknown component at the torque converter lockup input.
Current Output 9 Unknown ELC Comp Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location and see Retarder Control Harness (W6) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect torque converter lockup solenoid (Y68). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of torque converter lockup (WK) solenoid (Y68). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace torque converter lockup (WK) solenoid (Y68).
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523240.03- TORQ CVTR Propvalve Voltage High 44
The torque converter lockup (WK) solenoid is short to power.
TORQ CVTR Propvalve Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect torque converter lockup (WK) solenoid (Y68). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y68). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace torque converter lockup (WK) solenoid (Y68). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0318 for voltage at pin 18 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0318 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 5 (circuit 0318) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0318 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 18 (circuit BRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
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Section 9001 page 231
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523240.05- TORQ CVTR Propvalve Current Low 44
The torque converter lockup (WK) solenoid is open.
TORQ CVTR Propvalve Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect torque converter lockup (WK) solenoid (Y68). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of torque converter lockup (WK) solenoid (Y68). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Open Circuit Check. NO:Replace torque converter lockup (WK) solenoid (Y68). ( 3 ) Open Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0318 for continuity between pin 5 of connector (X71) and pin 18 on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit 0318 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
Action: Disconnect torque converter lockup (WK) solenoid (Y68). See Retarder Control Harness (W6) Component Location . (Group <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
9015-10.) Check circuit BRN for continuity between pin 18 on harness (W5) side of connector (X72) and pin 1 on torque converter lockup (WK) solenoid (Y68) harness connector. Check circuit ORG for continuity between pin 24 on harness (W5) side of connector (X72) and pin 2 on torque converter lockup (WK) solenoid (Y68) harness connector. Is continuity indicated?
Result: YES:Program transmission control unit (TCU). NO:Circuits that do not indicate continuity are open in transmission control harness (W4). Repair circuits or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523240.06- TORQ CVTR Propvalve Voltage Low 44
The torque converter lockup (WK) solenoid is short to ground.
TORQ CVTR Propvalve Voltage Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect torque converter lockup (WK) solenoid (Y68). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of solenoid (Y68). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace torque converter lockup (WK) solenoid (Y68). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0318 for ground at pin 18 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0318 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 5 (circuit 0318) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0318 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 18 (circuit BRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
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Section 9001 page 235
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523240.08- TORQ CVTR Propvalve Short to ALT Valve 44
The transmission control unit (TCU) detects the torque converter lockup (WK) solenoid input is short to another solenoid.
TORQ CVTR Propvalve Short to ALT Valve Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Component Check. NO:Repair or replace connectors. ( 3 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect torque converter lockup (WK) solenoid (Y68). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of torque converter lockup (WK) solenoid (Y68). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Harness Check. NO:Replace torque converter lockup (WK) solenoid (Y68). ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
Section 9001 page 236
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 5 (circuit 0318) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0318 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 18 (circuit BRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 237
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523245.02- Current Output 10 Unknown ELC COMP 44
The transmission control unit (TCU) detects an unknown component at the retarder solenoid input.
Current Output 10 Unknown ELC COMP Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location and see Retarder Control Harness (W6) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect retarder solenoid (Y69). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of retarder solenoid (Y69). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
<- Go to Section TOC
Section 9001 page 238
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace retarder solenoid (Y69).
<- Go to Section TOC
Section 9001 page 239
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523245.03- Retarder Propvalve Voltage High 44
The retarder solenoid is short to power.
Retarder Propvalve Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect retarder solenoid (Y69). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of solenoid (Y69). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace retarder solenoid (Y69). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0317 for voltage at pin 17 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0317 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
Section 9001 page 240
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 9 (circuit 0317) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0317 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 17 (circuit GRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 241
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523245.05- Retarder Propvalve Current Low 44
The retarder solenoid is open.
Retarder Propvalve Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect retarder solenoid (Y69). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of retarder solenoid (Y69). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Open Circuit Check. NO:Replace retarder solenoid (Y69). ( 3 ) Open Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0317 for continuity between pin 9 of connector (X71) and pin 17 on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit 0317 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
Action: Disconnect retarder solenoid (Y69). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check circuit GRN for continuity between pin 17 on harness (W5) side of connector (X72) and pin 1 on retarder solenoid (Y69) <- Go to Section TOC
Section 9001 page 242
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
harness connector. Check circuit ORG for continuity between pin 24 on harness (W5) side of connector (X72) and pin 2 on retarder solenoid (Y69) harness connector. Is continuity indicated?
Result: YES:Program transmission control unit (TCU). NO:Circuits that do not indicate continuity are open in transmission control harness (W4). Repair circuits or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 243
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523245.06- Retarder Propvalve Voltage Low 44
The retarder solenoid is short to ground.
Retarder Propvalve Voltage Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect retarder solenoid (Y69). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of solenoid (Y69). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace retarder solenoid (Y69). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0317 for ground at pin 17 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0317 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
Section 9001 page 244
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 5 (circuit 0317) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0317 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 17 (circuit GRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 245
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523245.08- Retarder Propvalve Short to ALT Valve 44
The transmission control unit (TCU) detects the retarder solenoid input is short to another solenoid.
Retarder Propvalve Short to ALT Valve Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Component Check. NO:Repair or replace connectors. ( 3 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect retarder solenoid (Y69). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of retarder solenoid (Y69). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Harness Check. NO:Replace retarder solenoid (Y69). ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Check for continuity between pin 9 (circuit 0317) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0317 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 17 (circuit GRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) See Retarder Control Harness (W6) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 247
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523250.02- Current Output 11 Unknown ELC Comp 44
The transmission control unit (TCU) detects an unknown component at the inter-axle differential lock (IDL) solenoid input.
Current Output 11 Unknown ELC Comp Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 3 ) Internal Connector Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Go to Component Check. NO:Connect solenoids to proper connections if needed. Repair or replace connectors as needed. ( 4 ) Component Check
Action: Ignition OFF. Disconnect inter-axle differential lock (IDL) solenoid (Y70). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin A and pin B of inter-axle differential lock (IDL) solenoid (Y70). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification? <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Replace inter-axle differential lock (IDL) solenoid (Y70).
<- Go to Section TOC
Section 9001 page 249
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523250.03- DIF Lock Propvalve Voltage High 44
The inter-axle differential lock (IDL) solenoid is short to power.
DIF Lock Propvalve Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect inter-axle lock (IDL) solenoid (Y70). See Clutch Control Harness (W5) Component Location . (Group 9015-10. Measure resistance between pins A and B of solenoid (Y70). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace inter-axle lock (IDL) solenoid (Y70). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0316 for voltage at pin 16 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0316 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 12 (circuit 0316) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0316 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 16 (circuit BRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 251
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523250.05- DIF Lock Propvalve Current Low 44
The inter-axle differential lock (IDL) solenoid is open.
DIF Lock Propvalve Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect inter-axle differential lock (IDL) solenoid (Y70). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin A and pin B of inter-axle differential lock (IDL) solenoid (Y70). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Open Circuit Check. NO:Replace inter-axle differential lock (IDL) solenoid (Y70). ( 3 ) Open Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0316 for continuity between pin 12 of connector (X71) and pin 16 on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit 0316 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
Action: Disconnect inter-axle differential lock (IDL) solenoid (Y70). See Clutch Control Harness (W5) Component Location . (Group <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
9015-10.) Check circuit BRN for continuity between pin 16 on harness (W5) side of connector (X72) and pin A on inter-axle differential lock (IDL) solenoid (Y70) harness connector. Check circuit ORG for continuity between pin 24 on harness (W5) side of connector (X72) and pin B on inter-axle differential lock (IDL) solenoid (Y70) harness connector. Is continuity indicated?
Result: YES:Program transmission control unit (TCU). NO:Circuits that do not indicate continuity are open in transmission control harness (W4). Repair circuits or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523250.06- DIF Lock Propvalve Voltage Low 44
The inter-axle differential lock (IDL) solenoid is short to ground.
DIF Lock Propvalve Voltage Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect inter-axle differential lock (IDL) solenoid (Y70). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin A and pin B of solenoid (Y70). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace inter-axle differential lock (IDL) solenoid (Y70). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0316 for ground at pin 16 on harness (W4) side of connector (X72). Is ground present?
Result: YES:Circuit 0316 is short to ground in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 12 (circuit 0316) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0316 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 16 (circuit BRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523250.08- DIF Lock Propvalve Short to ALT Valve 44
The transmission control unit (TCU) detects the inter-axle differential lock (IDL) solenoid input is short to another solenoid.
DIF Lock Propvalve Short to ALT Valve Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Connector Check. ( 2 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Component Check. NO:Repair or replace connectors. ( 3 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect inter-axle differential lock (IDL) solenoid (Y70). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin A and pin B of inter-axle differential lock (IDL) solenoid (Y70). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Harness Check. NO:Replace inter-axle differential lock (IDL) solenoid (Y70). ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control <- Go to Section TOC
Section 9001 page 256
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 12 (circuit 0316) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0316 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 16 (circuit BRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 257
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523300.00- Trans Sump Oil Over Temperature 44
Transmission oil temperature in the oil sump exceeds 110°C (230°F).
Trans Sump Oil Over Temperature Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Oil Level and Type Check. ( 2 ) Oil Level and Type Check
Action: Check transmission oil type and level. See Transmission Oil . (Operator’s Manual.) Is transmission oil of correct type and at correct level?
Result: YES:Go to Transmission Oil Cooler Check. NO:If transmission oil is incorrect type, drain and refill with correct oil type. See Transmission Oil . (Operator’s Manual.) NO:If transmission oil level is low, fill to correct level. See Transmission Oil . (Operator’s Manual.) ( 3 ) Transmission Oil Cooler Check
Action: Check transmission oil cooler for excessive debris buildup. See Power Train Component Location . (Group 9020-15.) Is there excessive debris on the oil cooler?
Result: YES:Clean transmission oil cooler. See Clean Cooler Cores . (Operator’s Manual.) NO:Go to Component Check. ( 4 ) Component Check
Action: Ignition OFF. Disconnect transmission sump temperature sensor (B39). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of transmission sump temperature sensor (B39). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Transmission Cooling System Check. NO:Replace transmission sump temperature sensor (B39). <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
( 5 ) Transmission Cooling System Check
Action: Check transmission cooling system lines for kinks or damage. See Power Train Component Location . (Group 9020-15.) Are transmission cooling system lines free of kinks or damage?
Result: YES:Checks complete. NO:Repair or replace parts as necessary.
<- Go to Section TOC
Section 9001 page 259
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523300.16- Transmission Sump Oil Over Temperature 44
Transmission oil temperature in the oil sump exceeds 120°C (248°F).
Trans Sump Oil Over Temperature Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Oil Level and Type Check. ( 2 ) Oil Level and Type Check
Action: Check transmission oil type and level. See Transmission Oil . (Operator’s Manual.) Is transmission oil of correct type and at correct level?
Result: YES:Go to Transmission Oil Cooler Check. NO:If transmission oil is incorrect type, drain and refill with correct oil type. See Transmission Oil . (Operator’s Manual.) NO:If transmission oil level is low, fill to correct level. See Transmission Oil . (Operator’s Manual.) ( 3 ) Transmission Oil Cooler Check
Action: Check transmission oil cooler for excessive debris buildup. See Power Train Component Location . (Group 9020-15.) Is there excessive debris on the oil cooler?
Result: YES:Clean transmission oil cooler. See Clean Cooler Cores . (Operator’s Manual.) NO:Go to Component Check. ( 4 ) Component Check
Action: Ignition OFF. Disconnect transmission sump temperature sensor (B39). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of transmission sump temperature sensor (B39). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Transmission Cooling System Check. NO:Replace transmission sump temperature sensor (B39). <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
( 5 ) Transmission Cooling System Check
Action: Check transmission cooling system lines for kinks or damage. See Power Train Component Location . (Group 9020-15.) Are transmission cooling system lines free of kinks or damage?
Result: YES:Program transmission control unit (TCU). NO:Repair or replace parts as necessary.
<- Go to Section TOC
Section 9001 page 261
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523301.00- Retarder Oil Over Temperature 44
Transmission oil temperature in the oil sump exceeds 110°C (230°F).
Retarder Oil Over Temperature Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Oil Level and Type Check. ( 2 ) Oil Level and Type Check
Action: Check transmission oil type and level. See Transmission Oil . (Operator’s Manual.) Is transmission oil of correct type and at correct level?
Result: YES:Go to Transmission Oil Cooler Check. NO:If transmission oil is incorrect type, drain and refill with correct oil type. See Transmission Oil . (Operator’s Manual.) NO:If transmission oil level is low, fill to correct level. See Transmission Oil . (Operator’s Manual.) ( 3 ) Transmission Oil Cooler Check
Action: Check transmission oil cooler for excessive debris buildup. See Power Train Component Location . (Group 9020-15.) Is there excessive debris on the oil cooler?
Result: YES:Clean transmission oil cooler. See Clean Cooler Cores . (Operator’s Manual.) NO:Go to Component Check. ( 4 ) Component Check
Action: Ignition OFF. Remove retarder temperature sensor access plug on transmission. Disconnect retarder temperature sensor (B38). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of retarder temperature sensor (B38). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Transmission Cooling System Check. <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Replace retarder temperature sensor (B38). ( 5 ) Transmission Cooling System Check
Action: Check transmission cooling system lines for kinks or damage. See Power Train Component Location . (Group 9020-15.) Are transmission cooling system lines free of kinks or damage?
Result: YES:Checks complete. NO:Repair or replace parts as necessary.
<- Go to Section TOC
Section 9001 page 263
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523301.16- Retarder Oil Moderately Severe Over Temperature 44
Transmission oil temperature in the oil sump exceeds 120°C (248°F).
Retarder Oil Moderately Severe Over Temperature Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Oil Level and Type Check. ( 2 ) Oil Level and Type Check
Action: Check transmission oil type and level. See Transmission Oil . (Operator’s Manual.) Is transmission oil of correct type and at correct level?
Result: YES:Go to Transmission Oil Cooler Check. NO:If transmission oil is incorrect type, drain and refill with correct oil type. See Transmission Oil . (Operator’s Manual.) NO:If transmission oil level is low, fill to correct level. See Transmission Oil . (Operator’s Manual.) ( 3 ) Transmission Oil Cooler Check
Action: Check transmission oil cooler for excessive debris buildup. See Power Train Component Location . (Group 9020-15.) Is there excessive debris on the oil cooler?
Result: YES:Clean transmission oil cooler. See Clean Cooler Cores . (Operator’s Manual.) NO:Go to Component Check. ( 4 ) Component Check
Action: Ignition OFF. Remove retarder temperature sensor access plug on transmission. Disconnect retarder temperature sensor (B38). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of retarder temperature sensor (B38). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Transmission Cooling System Check. <- Go to Section TOC
Section 9001 page 264
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Replace retarder temperature sensor (B38). ( 5 ) Transmission Cooling System Check
Action: Check transmission cooling system lines for kinks or damage. See Power Train Component Location . (Group 9020-15.) Are transmission cooling system lines free of kinks or damage?
Result: YES:Program transmission control unit (TCU). NO:Repair or replace parts as necessary.
<- Go to Section TOC
Section 9001 page 265
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523302.00- Torque Converter Oil Over Temperature 44
Transmission oil temperature in the oil sump exceeds 110°C (230°F).
Torque Converter Oil Over Temperature Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Oil Level and Type Check. ( 2 ) Oil Level and Type Check
Action: Check transmission oil type and level. See Transmission Oil . (Operator’s Manual.) Is transmission oil of correct type and at correct level?
Result: YES:Go to Transmission Oil Cooler Check. NO:If transmission oil is incorrect type, drain and refill with correct oil type. See Transmission Oil . (Operator’s Manual.) NO:If transmission oil level is low, fill to correct level. See Transmission Oil . (Operator’s Manual.) ( 3 ) Transmission Oil Cooler Check
Action: Check transmission oil cooler for excessive debris buildup. See Power Train Component Location . (Group 9020-15.) Is there excessive debris on the oil cooler?
Result: YES:Clean transmission oil cooler. See Clean Cooler Cores . (Operator’s Manual.) NO:Go to Component Check. ( 4 ) Component Check
Action: Ignition OFF. Remove retarder temperature sensor access plug on transmission. Disconnect retarder temperature sensor (B38). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of retarder temperature sensor (B38). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Transmission Cooling System Check. <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Replace retarder temperature sensor (B38). ( 5 ) Transmission Cooling System Check
Action: Check transmission cooling system lines for kinks or damage. See Power Train Component Location . (Group 9020-15.) Are transmission cooling system lines free of kinks or damage?
Result: YES:Checks complete. NO:Repair or replace parts as necessary.
<- Go to Section TOC
Section 9001 page 267
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523302.16- Torque Converter Oil Moderately Severe Over Temperature 44
Transmission oil temperature in the oil sump exceeds 120°C (248°F).
Torque Converter Oil Moderately Severe Over Temperature Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Oil Level and Type Check. ( 2 ) Oil Level and Type Check
Action: Check transmission oil type and level. See Transmission Oil . (Operator’s Manual.) Is transmission oil of correct type and at correct level?
Result: YES:Go to Transmission Oil Cooler Check. NO:If transmission oil is incorrect type, drain and refill with correct oil type. See Transmission Oil . (Operator’s Manual.) NO:If transmission oil level is low, fill to correct level. See Transmission Oil . (Operator’s Manual.) ( 3 ) Transmission Oil Cooler Check
Action: Check transmission oil cooler for excessive debris buildup. See Power Train Component Location . (Group 9020-15.) Is there excessive debris on the oil cooler?
Result: YES:Clean transmission oil cooler. See Clean Cooler Cores . (Operator’s Manual.) NO:Go to Component Check. ( 4 ) Component Check
Action: Ignition OFF. Remove retarder temperature sensor access plug on transmission. Disconnect retarder temperature sensor (B38). See Retarder Control Harness (W6) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of retarder temperature sensor (B38). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Go to Transmission Cooling System Check. NO:Replace retarder temperature sensor (B38). ( 5 ) Transmission Cooling System Check
Action: Check transmission cooling system lines for kinks or damage. See Power Train Component Location . (Group 9020-15.) Are transmission cooling system lines free of kinks or damage?
Result: YES:Program transmission control unit (TCU). NO:Repair or replace parts as necessary.
<- Go to Section TOC
Section 9001 page 269
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523304.00- Filter Switch Signal Out of Range 44
The oil filter restriction switch signal is outside of the defined operating range.
Filter Switch Signal Out of Range Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of transmission filter restriction switch (B17). Are approximately 510 ohms present?
Result: YES:Go to Short Circuit Check—Short to Power. NO:Replace transmission filter restriction switch (B17). ( 3 ) Short Circuit Check—Short to Power
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit N13 YEL for voltage at pin 2 of transmission filter restriction switch (B17) connector. Are 6.3 volts or more present?
Result: YES:Circuit 0202 and/or N13 YEL is short to power. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Short Circuit Check—Short to Ground. ( 4 ) Short Circuit Check—Short to Ground
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check circuit N13 YEL for ground at pin 2 of transmission filter restriction switch (B17) connector. <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Is ground present?
Result: YES:Circuit 0202 and/or N13 YEL is short to ground. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 5 ) Open Circuit Check
Action: Ignition OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check for continuity between pin 2 (circuit N13 YEL) of transmission filter restriction switch (B17) and pin 25 (circuit 0202) on TCU connector (X71). Is continuity indicated?
Result: YES:Circuit 0202 and/or N13 YEL is open. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 6 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 25 (circuit 0202) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0202 and/or N13 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 271
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523305.00- Oil Filter Contaminated 44
Transmission control unit (TCU) detects that the transmission oil filter is restricted.
Oil Filter Contaminated Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Transmission Oil Filter Check. ( 2 ) Transmission Oil Filter Check
Action: Remove transmission oil filter. Check filter for clogging or restrictions. Is transmission oil filter clogged or restricted?
Result: YES:Replace transmission oil filter. See Replace Transmission Oil Filters . (Operator’s Manual.) NO:Go to Component Check. ( 3 ) Component Check
Action: Ignition OFF. Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check for resistance between pin 1 and pin 2 of transmission filter restriction switch (B17). Are approximately 510 ohms present?
Result: YES:Go to Open Circuit Check. NO:Replace transmission filter restriction switch (B17). ( 4 ) Open Circuit Check
Action: Ignition OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Disconnect transmission filter restriction switch (B17). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check for continuity between pin 2 (circuit N13 YEL) of transmission filter restriction switch (B17) and pin 25 (circuit 0202) on TCU connector (X71). Is continuity indicated? <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Circuit 0202 and/or N13 YEL is open. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU). 523310.00- Trans Input Torque Too High 44
The transmission control unit (TCU) received a transmission input torque via the CAN bus that exceeds the permissible maximum limits.
Trans Input Torque Too High Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 523100.03 or 523100.06 from the transmission control unit (TCU) present?
Result: YES:Correct DTC 523100.03 and/or 523100.06 and recheck diagnostic trouble codes. NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523320.15- Trans Output Overspeed 44
The transmission control unit (TCU) detects that the transmission output speed exceeds the permissible maximum limits.
Trans Output Overspeed Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active transmission control unit (TCU) or engine control unit (ECU) DTCs present?
Result: YES:Correct all active TCU and ECU codes and recheck diagnostic trouble codes. NO:Go to Vehicle Operation. ( 3 ) Vehicle Operation
Action: Clear diagnostic trouble codes. Operate the vehicle under normal conditions. Verify proper operating procedures are followed. Is DTC 523320.15 present?
Result: YES:Go to Connector Check. NO:Checks complete. ( 4 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Internal Connector Check. NO:Repair or replace connectors. ( 5 ) Internal Connector Check <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Action: Ignition OFF. Remove output speed sensor cover plate. See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) See Clutch Control Harness (W5) Component Location . (Group 9015-10.) See Retarder Control Harness (W6) Component Location . (Group 9015-10.) See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace output speed sensor (B43). NO:Connect sensor to proper connection if needed. Repair or replace connectors as needed.
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523360.09- Trans Calibration Data Lost 44
The transmission control unit (TCU) was not able to read the correct calibration parameters.
Trans Calibration Data Lost Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active transmission control unit (TCU) or engine control unit (ECU) DTCs present?
Result: YES:Correct all active TCU and ECU codes and recheck diagnostic trouble codes. NO:Go to Electronic Clutch Calibration Check. ( 3 ) Electronic Clutch Calibration Check
Action: Perform electronic clutch calibration. See Electronic Clutch Calibration . (Group 9020-15.) Does DTC code go away?
Result: YES:Program transmission control unit (TCU). NO:Go to Connector Check. ( 4 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to Transmission Solenoid and Sensor Check. NO:Repair or replace connectors. ( 5 ) Transmission Solenoid and Sensor Check
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Action: Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Measure resistance of each component across the corresponding pins located on the transmission side of the connector. See Transmission Solenoids and Sensors Tests . (Group 9015-20.) Do components check good for resistance values?
Result: YES:Go to Internal Connector Check. NO:Repair or replace component. ( 6 ) Internal Connector Check
Action: Ignition OFF. Remove output speed sensor cover plate. See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Verify correct connection; check connector for corrosion and terminals for proper tension. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) See Clutch Control Harness (W5) Component Location . (Group 9015-10.) See Retarder Control Harness (W6) Component Location . (Group 9015-10.) See Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) Do connectors test good?
Result: YES:Replace output speed sensor (B43). NO:Connect sensor to proper connection if needed. Repair or replace connectors as needed.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523400.09- Vehicle CAN Failure 44
The transmission control unit (TCU) has detected a CAN communication loss.
Vehicle CAN Failure Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active CAN communication codes?
Result: YES:Correct all other active CAN communication codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to CAN Circuit Check. NO:Repair or replace connectors. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523401.09- Service CAN Failure 44
The transmission control unit (TCU) has detected a CAN communication loss.
Service CAN Failure Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active CAN communication codes?
Result: YES:Correct all other active CAN communication codes. NO:Go to Connector Check. ( 3 ) Connector Check
Action: Disconnect transmission control unit (TCU) connector (X70) and transmission control harness-to-transmission valve control harness connector (X71). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check connectors for corrosion and check terminals for proper tension. See Connector Terminal Test . (Group 9015-20.) Do connectors test good?
Result: YES:Go to CAN Circuit Check. NO:Repair or replace connectors. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523402.09- ECU Connection Loss 44
The transmission control unit (TCU) has detected a CAN communication loss with the engine control unit (ECU).
ECU Connection Loss Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Controller Sensors Check. ( 2 ) Controller Sensors Check
Action: View the engine control unit (ECU) monitored outputs using the CAN monitor unit (CMU). See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) Does the monitor show ECU sensor readings?
Result: YES: Go to CAN Circuit Check . NO:Go to Fuse Check. ( 3 ) Fuse Check
Action: Access cab fuses. See Fuse and Relay Specifications . (Group 9015-10.) Remove fuses F14 and F28 and check for continuity. Is continuity indicated across both fuses?
Result: YES:Go to Circuit Check. NO:Replace fuse without continuity. ( 4 ) Circuit Check
Action: Ignition OFF. Disconnect ECU connector (X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Ignition ON. Check circuit P09 RED for voltage at pins 13, 14, 23, and 24 on ECU connector (X13). Check circuit P24 RED for voltage at pin 7 on ECU connector (X13). Is system voltage (approximately 24 volts) present?
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Go to next check. NO:Circuits without voltage indicated are open. Repair circuits or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
Action: Check circuit G17 BLK for ground at pins 27, 43, and 44 on ECU connector (X13). Is ground present?
Result: YES:Go to CAN Circuit Check. NO:Circuits without ground indicated are open. Repair circuits or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 5 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Replace engine control unit (ECU). NO:Repair CAN circuit and test.
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523403.09- VCU Connection Loss 44
The transmission control unit (TCU) has detected a CAN communication loss with the chassis control unit (CCU).
VCU Connection Loss Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Controller Sensors Check. ( 2 ) Controller Sensors Check
Action: View the chassis control unit (CCU) monitored outputs using the CAN monitor unit (CMU). See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Does the monitor show CCU sensor readings?
Result: YES: Go to CAN Circuit Check . NO:Go to Fuse Check. ( 3 ) Fuse Check
Action: Access cab fuses. See Fuse and Relay Specifications . (Group 9015-10.) Remove fuses F6, F7, and F21 and check for continuity. Is continuity indicated across both fuses?
Result: YES:Go to Circuit Check. NO:Replace fuse without continuity. ( 4 ) Circuit Check
Action: Ignition OFF. Disconnect CCU connectors (X21 and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit P60 RED for voltage at pin L1 on CCU connector (X21). Check circuit P61 RED for voltage at pin 2 on ECU connector (X23). Check circuit P65 RED for voltage at pin M1 on ECU connector (X21). Is system voltage (approximately 24 volts) present?
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Go to next check. NO:Circuit without voltage indicated is open. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
Action: Check circuit G39 BLK for voltage at pin M2 on CCU connector (X21). Check circuit G40 BLK for voltage at pin L2 on ECU connector (X21). Check circuit G41 BLK for voltage at pin 2 on ECU connector (X22). Is ground present?
Result: YES:Go to CAN Circuit Check. NO:Circuits without ground indicated are open. Repair circuits or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 5 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Replace chassis control unit (CCU). NO:Repair CAN circuit and test.
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523404.09- Park Brake Controller Connection Loss 44
The transmission control unit (TCU) has detected a CAN communication loss with the chassis control unit (CCU).
Park Brake Controller Connection Loss Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Controller Sensors Check. ( 2 ) Controller Sensors Check
Action: View the chassis control unit (CCU) monitored outputs using the CAN monitor unit (CMU). See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Does the monitor show CCU sensor readings?
Result: YES: Go to CAN Circuit Check . NO:Go to Fuse Check. ( 3 ) Fuse Check
Action: Access cab fuses. See Fuse and Relay Specifications . (Group 9015-10.) Remove fuses F6, F7, and F21 and check for continuity. Is continuity indicated across both fuses?
Result: YES:Go to Circuit Check. NO:Replace fuse without continuity. ( 4 ) Circuit Check
Action: Ignition OFF. Disconnect CCU connectors (X21 and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit P60 RED for voltage at pin L1 on CCU connector (X21). Check circuit P61 RED for voltage at pin 2 on ECU connector (X23). Check circuit P65 RED for voltage at pin M1 on ECU connector (X21). Is system voltage (approximately 24 volts) present?
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Go to next check. NO:Circuit without voltage indicated is open. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
Action: Check circuit G39 BLK for voltage at pin M2 on CCU connector (X21). Check circuit G40 BLK for voltage at pin L2 on ECU connector (X21). Check circuit G41 BLK for voltage at pin 2 on ECU connector (X22). Is ground present?
Result: YES:Go to CAN Circuit Check. NO:Circuits without ground indicated are open. Repair circuits or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 5 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Replace chassis control unit (CCU). NO:Repair CAN circuit and test.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523410.09- TC1 MSG Failure Invalid or Time-out 44
The transmission control unit (TCU) did not receive the TC1 message.
TC1 MSG Failure Invalid or Time-out Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523410.09 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active CAN communication codes?
Result: YES:Correct all other active CAN communication codes. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523413.09- EEC1 MSG Failure Invalid or Time-out 44
The transmission control unit (TCU) did not receive the EEC1 message from engine control unit (ECU).
EEC1 MSG Failure Invalid or Time-out Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523413.09 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active CAN communication codes?
Result: YES:Correct all other active CAN communication codes. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523414.09- EEC2 MSG Failure Invalid or Time-out 44
The transmission control unit (TCU) did not receive the EEC2 message from engine control unit (ECU).
EEC2 MSG Failure Invalid or Time-out Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523414.09 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active CAN communication codes?
Result: YES:Correct all other active CAN communication codes. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523415.09- EEC3 MSG Failure Invalid or Time-out 44
The transmission control unit (TCU) did not receive the EEC3 message from engine control unit (ECU).
EEC3 MSG Failure Invalid or Time-out Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523415.09 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active CAN communication codes?
Result: YES:Correct all other active CAN communication codes. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523416.09- EC1 MSG Failure Invalid or Time-out 44
The transmission control unit (TCU) did not receive the EC1 message from engine control unit (ECU).
EC1 MSG Failure Invalid or Time-out Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523416.09 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active CAN communication codes?
Result: YES:Correct all other active CAN communication codes. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523417.09- B MSG Failure Invalid or Time-out 44
The transmission control unit (TCU) did not receive the B message from chassis control unit (CCU).
B MSG Failure Invalid or Time-out Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523417.09 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active CAN communication codes?
Result: YES:Correct all other active CAN communication codes. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523418.09- EBC1 MSG Failure Invalid or Time-out 44
The transmission control unit (TCU) did not receive the EBC1 message from chassis control unit (CCU).
EBC1 MSG Failure Invalid or Time-out Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523418.09 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active CAN communication codes?
Result: YES:Correct all other active CAN communication codes. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523420.09- CCVS MSG Failure Invalid or Time-out 44
The transmission control unit (TCU) did not receive the CCVS message from chassis control unit (CCU).
CCVS MSG Failure Invalid or Time-out Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523420.09 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active CAN communication codes?
Result: YES:Correct all other active CAN communication codes. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523422.09- V1 MSG Failure Invalid or Time-out 44
The transmission control unit (TCU) did not receive the V1 message from chassis control unit (CCU).
V1 MSG Failure Invalid or Time-out Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523422.09 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active CAN communication codes?
Result: YES:Correct all other active CAN communication codes. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523424.09- TSC1R MSG Failure Invalid or Time-out 44
The transmission control unit (TCU) did not receive the TSC1R message.
TSC1R MSG Failure Invalid or Time-out Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523424.09 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active CAN communication codes?
Result: YES:Correct all other active CAN communication codes. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523426.09- JBERC1 MSG Failure Invalid or Time-out 44
The transmission control unit (TCU) did not receive the JBERC1 message.
JBERC1 MSG Failure Invalid or Time-out Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523426.09 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active CAN communication codes?
Result: YES:Correct all other active CAN communication codes. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Section 9001 - DIAGNOSTICS
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523427.09- JBRC MSG Failure Invalid or Time-out 44
The transmission control unit (TCU) did not receive the JBRC message.
JBRC MSG Failure Invalid or Time-out Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523427.09 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active CAN communication codes?
Result: YES:Correct all other active CAN communication codes. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test. 523470.19- Operation MODE CMD Invalid Command 44
The transmission control unit (TCU) detects the incorrect operating software installed. <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Operation MODE CMD Invalid Command Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523470.19 present?
Result: YES:Program transmission control unit (TCU) with correct operating software. NO:Checks complete. 523471.19- Transmission CMD Invalid Command 44
The transmission control unit (TCU) detects the incorrect operating software installed.
Transmission CMD Invalid Command Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523471.19 present?
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU) with correct operating software. NO:Checks complete. 523474.19- DIFF Lock CMD Invalid Command 44
The transmission control unit (TCU) detects the incorrect operating software installed.
DIFF Lock CMD Invalid Command Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523474.19 present?
Result: YES:Program transmission control unit (TCU) with correct operating software. NO:Checks complete. 523475.19- Torq Converter CMD Invalid Command 44
The transmission control unit (TCU) detects the incorrect operating software installed.
Torq Converter CMD Invalid Command Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523475.19 present?
Result: YES:Program transmission control unit (TCU) with correct operating software. NO:Checks complete. 523476.19- Retarder CMD Invalid Command 44
The transmission control unit (TCU) detects the incorrect operating software installed.
Retarder CMD Invalid Command Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523476.19 present?
Result: YES:Program transmission control unit (TCU) with correct operating software. NO:Checks complete. 523480.09- Machine Configuration Invalid 44
The transmission control unit (TCU) detects the incorrect operating software installed.
Machine Configuration Invalid Command Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”? <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523480.09 present?
Result: YES:Program transmission control unit (TCU) with correct operating software. NO:Checks complete. 523481.00- Testmode Not Active 44
The transmission control unit (TCU) requested test mode but was not able to meet allowed conditions.
Testmode Not Active Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523481.00 present?
Result: YES:Program transmission control unit (TCU) with correct operating software. NO:Checks complete.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523500.00- Overspeed Engine 44
The transmission control unit (TCU) received an engine speed signal that exceeds the safe operating limits for the transmission.
Overspeed Engine Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Engine Speed Check. ( 2 ) Engine Speed Check
Action: Operate the machine and verify that engine speed is not excessive and is within safe working limits. Does engine speed check within range of 900—2250 rpm?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Correct excessive engine speed and test. See Engine Slow and Fast Idle Speed Check . (Group 9010-25.) ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active ECU DTCs?
Result: YES:Correct all active DTCs and test. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523501.00- Engine Speed Limitation Fault 44
The transmission control unit (TCU) requires a limited engine speed and is not maintaining the required limit.
Engine Speed Limitation Not Effective Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Engine Speed Check. ( 2 ) Engine Speed Check
Action: Operate the machine and shift to neutral. Verify that engine speed is not too low and is within safe working limits. Does engine speed check within range of 900—2250 rpm?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Correct excessive engine speed and test. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active ECU DTCs?
Result: YES:Correct all active DTCs and test. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523502.00- Engine Speed Demand Fault 44
The transmission control unit (TCU) requires a certain engine speed. Engine controller does not set this speed.
Engine Speed Demand is Not Effective Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Engine Speed Check. ( 2 ) Engine Speed Check
Action: Operate the machine and shift to neutral. Verify that engine speed is not to low and is within safe working limits. Does engine speed check within range of 900—2250 rpm?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Correct excessive engine speed and test. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active ECU DTCs?
Result: YES:Correct all active DTCs and test. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523503.00- Engine Torque Limitation Fault 44
The transmission control unit (TCU) requires a limited engine torque and is not maintaining the required limit.
Engine Torque Limitation Not Effective Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Engine Speed Check. ( 2 ) Engine Speed Check
Action: Operate the machine and shift to neutral. Verify that engine speed is not to low and is within safe working limits. Does engine speed check within range of 900—2250 rpm?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Correct excessive engine speed and test. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active ECU DTCs?
Result: YES:Correct all active DTCs and test. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523504.00- Engine Torque Demand Fault 44
The transmission control unit (TCU) requires a certain engine torque. Engine controller does not set this torque.
Engine Torque Demand is Not Effective Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Engine Speed Check. ( 2 ) Engine Speed Check
Action: Operate the machine and shift to neutral. Verify that engine speed is not too low and is within safe working limits. Does engine speed check within range of 900—2250 rpm?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Correct excessive engine speed and test. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active ECU DTCs?
Result: YES:Correct all active DTCs and test. NO:Go to CAN Circuit Check. ( 4 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523505.00- Transmission Protection 44
The transmission control unit (TCU) shifts to neutral to protect the engine.
Neutral Shift For Engine Protection Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Gear Range Check. ( 2 ) Cycle Gear Range Check
Action: Cycle gear range from neutral to any given gear range. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523505.00 present?
Result: YES:Go to Engine Speed Check. NO:Checks complete. ( 3 ) Engine Speed Check
Action: Operate the machine and shift to neutral. Verify that engine speed is not too low and is within safe working limits. Does engine speed check within range of 900—2250 rpm?
Result: YES:Go to Cycle Ignition Check. NO:Correct excessive engine speed and test. ( 4 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523505.00 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 5 ) Diagnostic Trouble Code Check <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active sealed switch module (SSM) DTCs present?
Result: YES:Correct all active DTCs and test. NO:Go to Vehicle Operation. ( 6 ) Vehicle Operation
Action: Clear diagnostic trouble codes. Operate the vehicle under normal conditions. Verify proper operating procedures are followed. Is DTC 523505.00 present?
Result: YES:Program transmission control unit (TCU). NO:Checks complete.
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523506.00- Engine Brake Without Request 44
The transmission control unit (TCU) is requesting deactivation of engine brake but engine brake is still active.
Engine Brake Demand is Not Effective Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Engine Speed Check. ( 2 ) Engine Speed Check
Action: Operate the machine and shift to neutral. Verify that engine speed is not too low and is within safe working limits. Does engine speed check within range of 900—2250 rpm?
Result: YES:Go to Cycle Ignition Check. NO:Correct excessive engine speed and test. ( 3 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523506.00 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 4 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active sealed switch module (SSM) DTCs present?
Result: YES:Correct all active DTCs and test. NO:Go to Vehicle Operation. ( 5 ) Vehicle Operation
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Action: Clear diagnostic trouble codes. Operate the vehicle under normal conditions. Verify proper operating procedures are followed. Is DTC 523506.00 present?
Result: YES:Program transmission control unit (TCU). NO:Checks complete. 523600.00- Transmission Protection 44
The transmission control unit (TCU) has detected a safety related error.
Safety Function Error Diagnostic Procedure Alarm Level: Stop Indicator (red) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active communication, time-out, or check sum DTCs present?
Result: YES:Correct all active DTCs and test. NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test. 523600.01- Transmission Protection Movement 44
The transmission control unit (TCU) has detected unwanted movement and shut down TCU.
Transmission Protection—Unwanted Movement Diagnostic Procedure ( 1 ) Intermittent Check
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active communication, time-out, or check sum DTCs present?
Result: YES:Correct all active DTCs and test. NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test. 523600.02- Transmission Protection Limit Direction 44
The transmission control unit (TCU) has detected movement in wrong direction.
Transmission Protection—Movement in Wrong Direction Diagnostic Procedure ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active communication, time-out, or check sum DTCs present?
Result: YES:Correct all active DTCs and test. <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test. 523600.03- Transmission Protection Limit Acceleration 44
The transmission control unit (TCU) has safety limited transmission to block acceleration.
Transmission Protection—Limited Acceleration Blocked Diagnostic Procedure ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active communication, time-out, or check sum DTCs present?
Result: YES:Correct all active DTCs and test. NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test. 523600.04- Transmission Protection Limit Acceleration Downshift 44
The transmission control unit (TCU) has safely limited transmission acceleration downshift.
Transmission Protection—Limited Acceleration Downshift Diagnostic
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Procedure ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active communication, time-out, or check sum DTCs present?
Result: YES:Correct all active DTCs and test. NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test. 523600.05- Transmission Protection Reverse Output 44
The transmission control unit (TCU) has signaled wrong reverse signal broadcasted.
Transmission Protection—Wrong Reverse Output Diagnostic Procedure ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active communication, time-out, or check sum DTCs present?
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Correct all active DTCs and test. NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test. 523600.07- Transmission Protection Directional Change 44
The transmission control unit (TCU) has signaled an unwanted change of driving direction.
Transmission Protection—Unwanted Direction Change Diagnostic Procedure ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active communication, time-out, or check sum DTCs present?
Result: YES:Correct all active DTCs and test. NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test. 523600.09- Transmission Protection Torque Limit 44
The transmission control unit (TCU) signals to limit torque. <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Transmission Protection—Limits Torque Diagnostic Procedure ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active communication, time-out, or check sum DTCs present?
Result: YES:Correct all active DTCs and test. NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test. 523600.10- Transmission Protection Gear Engagement 44
The transmission control unit (TCU) limits gear engagement.
Transmission Protection—Limited Delay for Engaging in Gear Diagnostic Procedure ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active communication, time-out, or check sum DTCs present? <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
Result: YES:Correct all active DTCs and test. NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test. 523601.00- Safety Related Error In Transmission 44
The transmission control unit (TCU) has detected a clutch shift although no gear change is requested.
Safety Related Error In Transmission Diagnostic Procedure ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active communication, time-out, or check sum DTCs present?
Result: YES:Correct all active DTCs and test. NO:Go to Component Check. ( 3 ) Component Check
Action: Disconnect clutch solenoids (Y60—Y67). See Clutch Control Harness (W5) Component Location and see Retarder Control Harness (W6) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 of each solenoid. Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Program transmission control unit (TCU). NO:Replace solenoid not within specification. 523602.00- Safety ERR In Vehicle Comm <- Go to Section TOC
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
44
The transmission control unit (TCU) has detected a safety related error in the vehicle communication.
Safety ERR In Vehicle Comm Diagnostic Procedure ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active communication, time-out, or check sum DTCs present?
Result: YES:Correct all active DTCs and test. NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
Action: Perform CAN circuit test. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit and test. 523603.00- Safety Error Reaction Failed 44
The transmission control unit (TCU) internal supply voltage is not switched off when required.
Safety Error Reaction Failed Diagnostic Procedure Alarm Level: Stop Indicator (red) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Program transmission control unit (TCU).
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Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
523650.00- Neutral With Vehicle Movement 44
The transmission control unit (TCU) detected that neutral was selected while vehicle was in motion. →NOTE: This code only indicates machine movement while in neutral and does not indicate a machine malfunction in any way.
Neutral W/Vehicle Movement Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Cycle Ignition Check. ( 2 ) Cycle Ignition Check
Action: Cycle ignition ON/OFF twice. Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is TCU code 523650.00 present?
Result: YES:Go to Diagnostic Trouble Code Check. NO:Checks complete. ( 3 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any active sealed switch module (SSM) DTCs present?
Result: YES:Correct all active DTCs and test. NO:Go to Vehicle Operation. ( 4 ) Vehicle Operation
Action: Clear diagnostic trouble codes. Operate the vehicle under normal conditions. Verify proper operating procedures are followed. Is DTC 523650.00 present?
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Result: YES:Program transmission control unit (TCU). NO:Checks complete.
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Group 20 - Engine Control Unit (ECU) Diagnostic Trouble Codes 000091.03- Throttle Input Sensor Voltage High 298
The accelerator pedal sensor (B18) circuit is short to power.
Throttle Input Sensor Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect accelerator pedal position sensor (B18). See Cab Harness (W3) Component Location . (Group 9015-10.) Check accelerator pedal position sensor (B18). See Electrical Component Specifications . (Group 9015-20.) Is sensor to specification?
Result: YES:Go to Short Circuit Check. NO:Replace accelerator pedal. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect accelerator pedal sensor (B18). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect ECU connector (X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Ignition ON. Check circuit E09 WHT for voltage at pin 10 of ECU connector (X13). Is voltage present?
Result: YES:Circuit E09 WHT is short to power. Repair circuit or replace harness. NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect accelerator pedal sensor (B18). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect engine control unit (ECU) connectors (X11, X12, and X13). See Engine Interface Harness (W18) Component Location <- Go to Section TOC
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
. (Group 9015-10.) Check for continuity between pin 10 (circuit E09 WHT) on ECU connector (X13) and all other pins on ECU connectors (X11, X12, and X13). Is continuity indicated with any pins?
Result: YES:Circuit E09 WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) NO:Program engine control unit (ECU).
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
000091.04- Throttle Input Sensor Voltage Low 298
Accelerator pedal sensor (B18) circuit is open or short to ground.
Throttle Input Sensor Voltage Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect accelerator pedal position sensor (B18). See Cab Harness (W3) Component Location . (Group 9015-10.) Check accelerator pedal position sensor (B18). See Electrical Component Specifications . (Group 9015-20.) Is sensor to specification?
Result: YES:Go to Open Circuit Check. NO:Replace accelerator pedal. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect accelerator pedal sensor (B18). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect engine control unit (ECU) connector (X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check circuit E09 WHT for continuity between pin A on pedal sensor (B18) harness connector and pin 10 on ECU connector (X13). Check circuit E07 WHT for continuity between pin C on pedal sensor (B18) harness connector and pin 49 on ECU connector (X13). Check circuit E08 WHT for continuity between pin B on pedal sensor (B18) harness connector and pin 33 on ECU connector (X13). Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Circuit without continuity indicated is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) ( 4 ) Short Circuit Check
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Action: Ignition OFF. Disconnect accelerator pedal sensor (B18). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit E09 WHT for ground at pin A on pedal sensor (B18) harness connector. Is ground present?
Result: YES:Circuit E09 WHT is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 5 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect accelerator pedal sensor (B18). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect engine control unit (ECU) connectors (X11, X12, and X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check for continuity between pin 10 (circuit E09 WHT) on ECU connector (X13) and all other pins on ECU connectors (X11, X12, and X13). Is continuity indicated with any pins?
Result: YES:Circuit E09 WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) NO:Program engine control unit (ECU).
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
000111.01- Coolant Level Very Low 298
The ECU detects a low coolant level at high coolant temperature.
Coolant Level Very Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Verify Problem
Action: →NOTE: When DTCs are cleared, snapshot information for ALL DTCs is cleared. Connect Service ADVISOR ™ , see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Ignition ON, engine OFF. If any DTCs have snapshot capture or snapshot recording information, save the information. For instructions on saving and using snapshot information, see Snapshot Instructions . (CTM104919.) In Service ADVISOR™, perform Control Unit Information and Overview test. Check engine coolant surge tank for correct coolant fill level. Is engine coolant level within the normal range?
Result: YES:Go to Switch Status Check. NO: Go to Cooling System Test . (CTM104919.) ( 2 ) Switch Status Check
Action: Ignition ON, engine OFF. In Service ADVISOR™, monitor engine coolant level alarm switch status. Is engine coolant level alarm switch status Low?
Result: YES:Go to Verify Trim Settings. NO: Go to Intermittent Short to Voltage Check . ( 3 ) Verify Trim Settings
Action: Verify that ECU trim page has been set up correctly for the John Deere OEM surge tank and level switches. Are the trim settings correct?
Result: YES:Go to Terminal Test. NO:Reprogram ECU with correct trim settings. ( 4 ) Terminal Test
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Action: Ignition OFF, engine OFF. Disconnect engine coolant loss alarm switch (B20). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Perform Connector Terminal Test on switch (B20). Were any problems found?
Result: YES:Repair problem. Perform Verification Procedure . (CTM104919.) NO:Go to Component Check. ( 5 ) Component Check
Action: Ignition OFF. Disconnect engine coolant loss alarm switch (B20). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check switch (B20) for continuity between pins 1 and 2 on switch connector. Is continuity indicated?
Result: YES:Go to Open Circuit Check. NO:Replace engine coolant loss alarm switch (B20). ( 6 ) Open Circuit Check
Action: Ignition OFF. Disconnect engine coolant loss alarm switch (B20) and engine control unit (ECU) connector (X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check circuit Y03 YEL for continuity between pin 1 on switch (B20) harness connector and pin 22 on ECU connector (X13). Check circuit G18 BLK for continuity between pin 2 on switch (B20) harness connector and machine ground. Is continuity indicated?
Result: YES:Go to Intermittent Short to Voltage Check. NO:Circuit without continuity indicated is open. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) ( 7 ) Intermittent Short to Voltage Check
Action: In Service ADVISOR ™ , monitor engine coolant level alarm switch status. Perform Wiggle Test . (CTM104919.) Does engine coolant level alarm switch status ever display Low?
Result: YES:Repair harness problem. NO:Program engine control unit (ECU). <- Go to Section TOC
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<- Go to Section TOC
Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
000111.07- Coolant Level Mechanical Fault 298
Coolant switches indicate coolant level is below loss switch level but not below service switch level.
Coolant Level Mechanical Fault Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Coolant Level Check. ( 2 ) Coolant Level Check
Action: Check engine coolant level. See Check Engine Coolant Level . (Operator’s Manual.) Is engine coolant at correct level?
Result: YES:Go to Connector Mismatch Check. NO:Add engine coolant as necessary. See Heavy Duty Diesel Engine Coolant . (Operator’s Manual.) ( 3 ) Connector Mismatch Check
Action: Check engine coolant loss alarm switch (B20) connector and engine coolant loss service switch (B19) connector. See Engine Interface Harness (W18) Component Location and see Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) Are switch connectors switched?
Result: YES:Connect connectors to correct components. NO:Go to Component Check. ( 4 ) Component Check
Action: Ignition OFF. Disconnect engine coolant loss alarm switch (B20). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check switch (B20) for continuity between pins 1 and 2 on switch connector. Is continuity indicated?
Result: YES:Go to Open Circuit Check. NO:Replace engine coolant loss alarm switch (B20). ( 5 ) Open Circuit Check <- Go to Section TOC
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Action: Ignition OFF. Disconnect engine coolant loss alarm switch (B20) and engine control unit (ECU) connector (X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check circuit Y03 YEL for continuity between pin 1 on switch (B20) harness connector and pin 22 on ECU connector (X13). Check circuit G18 BLK for continuity between pin 2 on switch (B20) harness connector and machine ground. Is continuity indicated?
Result: YES:Program engine control unit (ECU). NO:Circuit without continuity indicated is open. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.)
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
000111.17- Coolant Level Slightly Low 298
Coolant level is below coolant service switch level at startup.
Coolant Level Slightly Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Coolant Level Check. ( 2 ) Coolant Level Check
Action: Check engine coolant level. See Check Engine Coolant Level . (Operator’s Manual.) Is engine coolant at correct level?
Result: YES:Go to Component Check. NO:Add engine coolant as necessary. See Heavy Duty Diesel Engine Coolant . (Operator’s Manual.) ( 3 ) Component Check
Action: Ignition OFF. Disconnect engine coolant loss service switch (B19). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check switch (B19) for continuity between pins 1 and 2 on switch connector. Is continuity indicated?
Result: YES:Go to Open Circuit Check. NO:Replace engine coolant loss service switch (B19). ( 4 ) Open Circuit Check
Action: Ignition OFF. Disconnect engine coolant loss service switch (B19) and engine control unit (ECU) connector (X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check circuit Y02 YEL for continuity between pin 1 on switch (B19) harness connector and pin 38 on ECU connector (X13). Check circuit G18 BLK for continuity between pin 2 on switch (B19) harness connector and machine ground. Is continuity indicated?
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Result: YES:Program engine control unit (ECU). NO:Circuit without continuity indicated is open. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.)
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
000111.18- Engine Coolant Level Moderately Low 298
Coolant temperature is greater than 60°C (140°F) and coolant is below loss switch level.
Engine Coolant Level Moderately Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Verify Problem
Action: →NOTE: When DTCs are cleared, snapshot information for ALL DTCs is cleared. Connect Service ADVISOR ™ , see Service ADVISOR™ Connection Procedure . (Group 9015-20.) Ignition ON, engine OFF. If any DTCs have snapshot capture or snapshot recording information, save the information. For instructions on saving and using snapshot information, see Snapshot Instructions . (CTM104919.) In Service ADVISOR™, perform Control Unit Information and Overview test. Check engine coolant surge tank for correct coolant fill level. Is engine coolant level within the normal range?
Result: YES:Go to Switch Status Check. NO: Go to Cooling System Test . (CTM104919.) ( 2 ) Switch Status Check
Action: Ignition ON, engine OFF. In Service ADVISOR™, monitor engine coolant level alarm switch status. Is engine coolant level alarm switch status Low?
Result: YES:Go to Verify Trim Settings. NO: Go to Intermittent Short to Voltage Check . ( 3 ) Verify Trim Settings
Action: Verify that ECU trim page has been set up correctly for the John Deere OEM surge tank and level switches. Are the trim settings correct?
Result: YES:Go to Terminal Test. NO:Reprogram ECU with correct trim settings. ( 4 ) Terminal Test
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Action: Ignition OFF, engine OFF. Disconnect engine coolant loss alarm switch (B20). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Perform Connector Terminal Test on switch (B20). Were any problems found?
Result: YES:Repair problem. Perform Verification Procedure . (CTM104919.) NO:Go to Component Check. ( 5 ) Component Check
Action: Ignition OFF. Disconnect engine coolant loss alarm switch (B20). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check switch (B20) for continuity between pins 1 and 2 on switch connector. Is continuity indicated?
Result: YES:Go to Open Circuit Check. NO:Replace engine coolant loss alarm switch (B20). ( 6 ) Open Circuit Check
Action: Ignition OFF. Disconnect engine coolant loss alarm switch (B20) and engine control unit (ECU) connector (X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check circuit Y03 YEL for continuity between pin 1 on switch (B20) harness connector and pin 22 on ECU connector (X13). Check circuit G18 BLK for continuity between pin 2 on switch (B20) harness connector and machine ground. Is continuity indicated?
Result: YES:Go to Intermittent Short to Voltage Check. NO:Circuit without continuity indicated is open. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) ( 7 ) Intermittent Short to Voltage Check
Action: In Service ADVISOR™, monitor engine coolant level alarm switch status. Perform Wiggle Test . (CTM104919.) Does engine coolant level alarm switch status ever display Low?
Result: YES:Repair harness problem. NO:Program engine control unit (ECU). <- Go to Section TOC
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<- Go to Section TOC
Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
000157.16- Fuel Rail Pressure Very High 299
The high-pressure fuel pressure sensor (B5107) detects pressure above normal operating range.
High-Pressure Fuel Pressure Sensor (B5107) Circuit Schematic LEGEND: A3 B5107 X12
Engine Control Unit (ECU) High-Pressure Fuel Pressure Sensor Engine Control Unit (ECU) Connector
Alarm Level: Red Stop Lamp Machine Response: None Circuit Information: See High-Pressure Fuel System Operation . (CTM 104919.) Component Location: See Engine Harness (W17) Component Location . (Group 9015-10.) See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Diagnostic Test Box Information: None Additional References: See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Possible Causes: 1. Fuel pressure is high. 2. Component malfunction. See Electrical Component Specifications . (Group 9015-20.) 3. Software malfunction. Program controller.
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
000157.17- Fuel Rail Pressure Low when Starting 299
Low fuel pressure detected by high-pressure fuel pressure sensor (B5107) during or immediately following engine crank.
High-Pressure Fuel Pressure Sensor (B5107) Circuit Schematic LEGEND: A3 B5107 X12
Engine Control Unit (ECU) High-Pressure Fuel Pressure Sensor Engine Control Unit (ECU) Connector
Alarm Level: Red Stop Lamp Machine Response: None Circuit Information: See High-Pressure Fuel System Operation . (CTM 104919.) Component Location: See Engine Harness (W17) Component Location . (Group 9015-10.) See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Diagnostic Test Box Information: None Additional References: See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Possible Causes: 1. Low fuel level. 2. Restricted fuel filters. 3. Component malfunction. See Electrical Component Specifications . (Group 9015-20.) 4. Software malfunction. Program controller. 000168.16- Battery Voltage High 298
Battery voltage is moderately high.
Battery Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: <- Go to Section TOC
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Voltage Check. ( 2 ) Voltage Check
Action: Start engine. Check voltage at batteries. Are 31 volts or more present?
Result: YES:Go to Alternator Check. NO:Program engine control unit (ECU). ( 3 ) Alternator Check
Action: Perform Alternator Test . (Group 9015-20.) Does alternator test good?
Result: YES:Program engine control unit (ECU). NO:Replace alternator. 000168.18- Battery Voltage Low 298
Battery voltage is moderately low.
Battery Voltage Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Battery Check
Action: Check batteries for voltage separately. See Handling, Checking and Servicing Batteries Carefully . (Operator′s Manual.) Do batteries test good?
Result: YES:Go to Component Check. NO:Replace batteries. ( 2 ) Component Check
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Action: Check the serpentine belt for proper tension and performance. See Inspect Serpentine Belt . (Operators Manual.) Does the serpentine belt test good?
Result: YES:Go to Alternator Check. NO:Replace the serpentine belt. See Serpentine Belt Remove and Install . (Group 0510.) ( 3 ) Alternator Check
Action: Perform Alternator Test . (Group 9015-20.) Does alternator test good?
Result: YES:Checks complete. NO:Replace alternator. 000190.16- Engine Overspeed Moderately High 298
Engine overspeed is moderately high.
Engine Overspeed Moderately High Diagnostic Procedure Alarm Level: Caution Indicator (red) Additional References: For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check for active engine control unit (ECU) diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any of the following engine control unit (ECU) codes present? 000636.02 000636.10 000637.02 000637.07 000190.00
Result: YES:Correct problems causing other ECU diagnostic trouble codes. NO:Checks complete.
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
001321.03- Starter Relay Voltage High 298
Starter relay voltage is high, indicating possible short to power in circuit.
Starter Relay Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow). Additional References: For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect starter relay (K2). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Apply 24 V to the coil and ground of starter relay (K2). Check continuity across pins 30 and 87 of starter relay (K2). Is continuity indicated?
Result: YES:Go to Voltage Check. NO:Starter relay (K2) malfunction. Replace relay. ( 3 ) Voltage Check
Action: Ignition OFF. Disconnect starter relay (K2) from harness. See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Ignition ON. Check circuit E04 WHT for voltage at pin 30 of starter relay (K2) harness connector. Is voltage (approximately 24 volts) present?
Result: YES:Circuit E04 WHT is short to power. Repair or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect starter relay (K2) and engine control unit (ECU) connectors (X11, X12, and X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check for continuity between pin 30 (circuit E04 WHT) on ECU connector (X13) and all other pins on ECU connectors (X11, X12, <- Go to Section TOC
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
and X13). Is continuity indicated?
Result: YES:Circuit E04 WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) NO:Engine control unit malfunction. Reprogram engine control unit.
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
001321.04- Starter Relay Voltage Low 298
Starter relay voltage low.
Starter Relay Voltage Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect starter relay (K2). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Apply 24 V to the coil and ground of starter relay (K2). Check continuity across pins 30 and 87 of starter relay (K2). Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Starter relay (K2) malfunction. Replace relay. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect starter relay (K2) from harness. See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Ignition ON. Check circuit E04 WHT for ground at pin 30 of starter relay (K1) harness connector. Is ground present?
Result: YES:Circuit E04 WHT is short to ground. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect starter relay (K2) and engine control unit (ECU) connectors (X11, X12, and X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check for continuity between pin 30 (circuit E04 WHT) on ECU connector (X13) and all other pins on ECU connectors (X11, X12, <- Go to Section TOC
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
and X13). Is continuity indicated?
Result: YES:Circuit E04 WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) NO:Engine control unit malfunction. Reprogram engine control unit. 001321.05- Starter Relay Current Low 298
The starter relay current is too low.
Starter Relay Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect starter relay (K2). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Apply 24 V to the coil and ground of starter relay (K2). Check continuity across pins 30 and 87 of starter relay (K2). Is continuity indicated?
Result: YES:Go to Harness Check. NO:Starter relay (K2) malfunction. Replace relay. ( 3 ) Harness Check
Action: Ignition OFF. Disconnect starter relay (K2) and engine control unit (ECU) connector (X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check circuit E04 WHT for continuity between pin 30 on ECU connector (X13) and starter relay (K2) harness connector. Is continuity indicated?
Result: YES:Engine control unit malfunction. Reprogram engine control unit. NO:Circuit E04 WHT is open. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
001321.06- Starter Relay Current High 298
Starter relay current high.
Starter Relay Current High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect starter relay (K2). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Apply 24 V to the coil and ground of starter relay (K2). Check continuity across pins 30 and 87 of starter relay (K2). Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Starter relay (K2) malfunction. Replace relay. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect starter relay (K2) from harness. See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Ignition ON. Check circuit E04 WHT for ground at pin 30 of starter relay (K1) harness connector. Is ground present?
Result: YES:Circuit E04 WHT is short to ground. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect starter relay (K2) and engine control unit (ECU) connectors (X11, X12, and X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check for continuity between pin 30 (circuit E04 WHT) on ECU connector (X13) and all other pins on ECU connectors (X11, X12, <- Go to Section TOC
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
and X13). Is continuity indicated?
Result: YES:Circuit E04 WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) NO:Engine control unit malfunction. Reprogram engine control unit. 001321.16- Starter Relay Start Time Moderately High 298
Starter was engaged for 30 or more seconds.
Starter Relay Start Time Moderately High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Functional Check
Action: Observe engine and engine cranking time at start-up. Did diagnostic trouble code 001321.16—Starter Relay Start Time Moderately High appear after cranking engine for 30 seconds?
Result: YES:Starter protection system functioning correctly. NO:Short to power on E04 WHT wire between starter relay and engine control unit. Repair or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.)
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
002033.19- CCU CAN Communication Error 298
Controller area network (CAN) communication error; the engine control unit (ECU) lost communication with the chassis control unit (CCU).
CCU CAN Communication Error Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-10.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Controller Sensors Check. ( 2 ) Controller Sensors Check
Action: Connect Service ADVISOR ™ . See Service ADVISOR™ Connection Procedure . (Group 9015-20.) View CCU input sensor data on Service ADVISOR™. Are all CCU sensor values displayed?
Result: YES:Program engine control unit (ECU). NO:Go to Fuse Check. ( 3 ) Fuse Check
Action: Ignition OFF. Remove fuses (F6, F7, and F21). See Fuse and Relay Specifications . (Group 9015-10.) Check fuses (F6, F7, and F21) for continuity. Is continuity indicated?
Result: YES:Go to Voltage Check. NO:Fuse without continuity indicated is faulty. Replace fuse. ( 4 ) Voltage Check
Action: Ignition OFF. Disconnect CCU connectors (X21 and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check the following circuits for voltage: Circuit P65 RED at pin M1 on connector (X21) Circuit P60 RED at pin L1 on connector (X21) Circuit P61 GRN at pin 2 on connector (X23) <- Go to Section TOC
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Is system voltage (approximately 24 volts) present at all pins?
Result: YES:Go to Ground Circuit Check. NO:Circuit without voltage present is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 5 ) Ground Circuit Check
Action: Ignition OFF. Disconnect CCU connectors (X21 and X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check the following circuits for ground. Circuit G40 BLK at pin L2 on connector (X21) Circuit G39 BLK at pin M2 on connector (X21) Circuit G41 BLK at pin 2 on connector (X22) Is ground present?
Result: YES:Go to CAN Circuit Check. NO:Circuit without ground present is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 6 ) CAN Circuit Check
Action: Test controller area network (CAN) circuit. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program chassis control unit (CCU). NO:Repair CAN circuit.
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
003353.31- No Alternator Condition Exists 298
Alternator output voltage is low for greater than 10 seconds.
No Alternator Condition Exists Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Start and Charge Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Belt Check. ( 2 ) Belt Check
Action: Inspect serpentine belt. See Inspect Serpentine Belt . (Operator’s Manual.) Is serpentine belt routed correctly and in good condition?
Result: YES:Go to Component Check. NO:Replace serpentine belt. See Serpentine Belt Remove and Install . (Group 0510.) ( 3 ) Component Check
Action: Test alternator. See Alternator Test . (Group 9015-20.) Does alternator test good?
Result: YES:Go to Open Circuit Check. NO:Replace alternator. ( 4 ) Open Circuit Check
Action: Ignition OFF. Disconnect alternator D+ terminal and engine control unit (ECU) connector (X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check circuit J03 TAN for continuity between D+ ring terminal and pin 29 on ECU connector (X13). Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Circuit J03 TAN is open. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) ( 5 ) Short Circuit Check <- Go to Section TOC
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
Action: Ignition OFF. Disconnect alternator D+ terminal and engine control unit (ECU) connector (X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check circuit J03 TAN for ground at pin 29 on ECU connector (X13). Is ground present?
Result: YES:Circuit J03 TAN is short to ground. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) NO:Checks complete.
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Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
003587.06- Ether Start Aid Solenoid Current High 298
Ether start aid solenoid circuit is short to ground.
Ether Start Aid Solenoid Current High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Cold Start Aid Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect ether start aid solenoid (Y15). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Measure resistance between pins A and B on solenoid (Y15). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Ether start aid solenoid malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect ether start aid solenoid (Y15) and engine control unit (ECU) connector (X11). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check circuit 5429 WHT for ground at pin 46 on ECU connector (X11). Is ground present?
Result: YES:Circuit 5429 WHT is short to ground. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect ether start aid solenoid (Y15) and engine control unit (ECU) connectors (X11, X12, and X13). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check for continuity between pin 46 (circuit 5429 WHT) on ECU connector (X11) and all other pins on ECU connectors (X11, <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
X12, and X13). Is continuity indicated?
Result: YES:Circuit 5429 WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Engine Interface Harness (W18) Wiring Diagram . (Group 9015-10.) NO:Checks complete. 003719.15- DPF Soot Load Above Normal Operating Level 298
DPF soot level is slightly high.
DPF Soot Load Above Normal Operating Level Diagnostic Procedure Alarm Level: Exhaust Filter Indicator Additional References: For additional information, see Exhaust Aftertreatment Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Auto Cleaning Enable Check
Action: Enable auto filter cleaning in the CAN monitor unit (CMU). See CAN Monitor Unit (CMU)—Main Menu—Exhaust Filter—Auto Cleaning . (Operator’s Manual.) Is a filter cleaning initiated?
Result: YES:Checks complete. NO:Perform a parked filter cleaning. See CAN Monitor Unit (CMU)—Exhaust Filter . (Group 9015-16.)
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Group 30 - Chassis Control Unit (CCU) Diagnostic Trouble Codes 000096.03- Fuel Level Sensor Voltage High 11
The fuel level sensor signal voltage is greater than 1.8 volts.
Fuel Level Sensor Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect fuel level sensor (B37). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on fuel level sensor (B37). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Open Circuit Check. NO:Replace fuel level sensor (B37). ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect fuel level sensor (B37). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit Y01 YEL for continuity between pin 1 on sensor (B37) harness connector and pin 7 on chassis control unit (CCU) connector (X23). Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 4 ) Short Circuit Check
Action: Ignition OFF. Disconnect fuel level sensor (B37). See Front Frame Harness (W2) Component Location . (Group 9015-10.) <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit Y01 YEL for voltage at pin 1 on fuel level sensor (B37) harness connector. Is voltage present?
Result: YES:Circuit Y01 YEL is short to power. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 5 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect fuel level sensor (B37). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 7 (circuit Y01 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit Y01 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
000096.04- Fuel Level Sensor Voltage Low 11
The fuel level sensor circuit signal voltage is less than 0.07 volts.
Fuel Level Sensor Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect fuel level sensor (B37). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance between terminals on fuel level sensor (B37). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Replace fuel level sensor (B37). ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect fuel level sensor (B37). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check circuit Y01 YEL for ground at pin 1 of fuel level sensor (B37) harness connector. Is ground present?
Result: YES:Circuit Y01 YEL is short to ground. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect fuel level sensor (B37). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 7 (circuit Y01 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit Y01 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
000116.01- Brake Pressure Very Low 11
The brake accumulator low pressure switch is open with engine running for more that 60 seconds or brake accumulator low pressure switch is open with park brake release requested.
Brake Pressure Very Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Fuse Check. ( 2 ) Fuse Check
Action: Access cab fuses. See Fuse and Relay Specifications . (Group 9015-10.) Remove seat compressor and brake accumulator low pressure switch 10-amp fuse (F30). Check fuse (F30) for continuity. Is continuity indicated across fuse (F30)?
Result: YES:Go to Component Check. NO:Replace seat compressor and brake accumulator low pressure switch 10-amp fuse (F30). ( 3 ) Component Check
Action: Ignition OFF. Disconnect brake accumulator low pressure switch (B35). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Test switch. See Electrical Component Specifications . (Group 9015-20.) Does switch test good?
Result: YES:Go to Open Circuit Check. NO:Replace accumulator low pressure switch (B35). ( 4 ) Open Circuit Check
Action: Ignition OFF. Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect brake accumulator low pressure switch (B35). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check circuit N15 YEL for continuity between pin 1 on sensor (B35) harness connector and pin 26 of CCU connector (X23). Is continuity indicated?
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) 000237.31- Model Unknown 11
The model number and VIN number is missing in the chassis control unit (CCU).
Model Unknown Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO: ( 2 ) Program Controller
Action: Program the chassis control unit (CCU). Is DTC 000237.31 still active?
Result: YES:Replace chassis control unit (CCU). NO:Checks complete.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
000241.01- Tire Pressure Very Low 11
Tire pressure data is valid, but below normal operating range.
Tire Pressure Very Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see the following: Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) Tire Pressure Monitoring (TPM) System Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Pressure Check. ( 2 ) Pressure Check
Action: Ignition ON. Identify tire with low pressure by viewing tire data in the CAN monitor unit (CMU). See CAN monitor unit (CMU)—Machine Options . (Group 9015-16.) Is tire pressure low on specified tire?
Result: YES:Add air until tire pressure is to specification. NO:Go to Cold Inflation Pressure Setup. ( 3 ) Cold Inflation Pressure Setup
Action: Check the cold inflation pressure (CIP) set point on tire that indicated low pressure. See TPM—Cold Inflation Pressure (CIP) Setup . (Group 9015-20.) Is cold inflation pressure set to manufacturer specification?
Result: YES:Go to Program Sensor. NO:Adjust CIP set point. See TPM—Cold Inflation Pressure (CIP) Setup . (Group 9015-20.) ( 4 ) Program Sensor
Action: Program the pressure sensor on tire that indicated low pressure. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) Does pressure sensor program on the tire that indicated low pressure?
Result: YES:Go to Clear Codes and Retest. <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
NO:Replace pressure and program new sensor. See TPM—Tire Pressure Sensor Remove and Install , and See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) ( 5 ) Clear Codes and Retest
Action: Clear codes. See CAN monitor unit (CMU)—Codes . (Group 9015-16.) Operate machine for 5 minutes and check codes. Is code 000241.01 still present?
Result: YES:Replace pressure and program new sensor. See TPM—Tire Pressure Sensor Remove and Install , and See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) NO:Checks complete.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
000241.16- Tire Pressure Moderately High 11
Tire pressure data is valid, but above normal operating temperature.
Tire Pressure Moderately High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Pressure Check. ( 2 ) Pressure Check
Action: Ignition ON. Identify tire with low pressure by viewing tire data in the CAN monitor unit (CMU). See CAN monitor unit (CMU)—Machine Options . (Group 9015-16.) Check the tire pressure on identified tire. Is tire pressure high on specified tire?
Result: YES:Relieve pressure until tire is to specification. NO:Go to Cold Inflation Pressure Setup. ( 3 ) Cold Inflation Pressure Setup
Action: Check the cold inflation pressure (CIP) set point on tire that indicated low pressure. See TPM—Cold Inflation Pressure (CIP) Setup . (Group 9015-20.) Is cold inflation pressure set to manufacturer specification?
Result: YES:Go to Program Sensor. NO:Adjust CIP set point. See TPM—Cold Inflation Pressure (CIP) Setup . (Group 9015-20.) ( 4 ) Program Sensor
Action: Program the pressure sensor on tire that indicated low pressure. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) Does pressure sensor program on tire that indicated low pressure?
Result: YES:Go to Clear Codes and Retest. NO:Replace and program new sensor. See TPM—Tire Pressure Sensor Remove and Install , and See TPM—Programming <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) ( 5 ) Clear Codes and Retest
Action: Clear codes. See CAN monitor unit (CMU)—Codes . (Group 9015-16.) Operate machine for 5 minutes and check codes. Is code 000241.16 still present?
Result: YES:Replace and program new sensor. See TPM—Tire Pressure Sensor Remove and Install , and See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) NO:Checks complete.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
000241.18- Tire Pressure Moderately Low 11
Tire pressure is data is valid, but below normal operating temperature.
Tire Pressure Moderately Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Pressure Check. ( 2 ) Pressure Check
Action: Ignition ON. Identify tire with low pressure by viewing tire data in the CAN monitor unit (CMU). See CAN monitor unit (CMU)—Machine Options . (Group 9015-16.) Is tire pressure low on specified tire?
Result: YES:Add air until tire pressure is to specification. NO:Go to Cold Inflation Pressure Setup. ( 3 ) Cold Inflation Pressure Setup
Action: Check the cold inflation pressure (CIP) set point on tire that indicated low pressure. See TPM—Cold Inflation Pressure (CIP) Setup . (Group 9015-20.) Is cold inflation pressure set to manufacturer specification?
Result: YES:Go to Program Sensor. NO:Adjust CIP set point. See TPM—Cold Inflation Pressure (CIP) Setup . (Group 9015-20.) ( 4 ) Program Sensor
Action: Program the pressure sensor on tire that indicated low pressure. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) Does pressure sensor program on tire that indicated low pressure?
Result: YES:Go to Clear Codes and Retest. NO:Replace and program new sensor. See TPM—Tire Pressure Sensor Remove and Install , and See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
( 5 ) Clear Codes and Retest
Action: Clear codes. See CAN monitor unit (CMU)—Codes . (Group 9015-16.) Operate machine for 5 minutes and check codes. Is code 000241.18 still present?
Result: YES:Replace and program new sensor. See TPM—Tire Pressure Sensor Remove and Install , and See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) NO:Checks complete.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
000242.16- Tire Temperature Moderately High 11
Tire temperature data is valid, but above normal operating temperature.
Tire Temperature Moderately High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Pressure Check. ( 2 ) Pressure Check
Action: Ignition ON. Identify tire with low pressure by viewing tire data in the CAN monitor unit (CMU). See CAN monitor unit (CMU)—Machine Options . (Group 9015-16.) Check the tire pressure on identified tire. Is tire pressure high on specified tire?
Result: YES:Relieve pressure until tire is to specification. NO:Go to Cold Inflation Pressure Setup. ( 3 ) Cold Inflation Pressure Setup
Action: Check the cold inflation pressure (CIP) set point on tire that indicated low pressure. See TPM—Cold Inflation Pressure (CIP) Setup . (Group 9015-20.) Is cold inflation pressure set to manufacturer specification?
Result: YES:Go to Program Sensor. NO:Adjust CIP set point. See TPM—Cold Inflation Pressure (CIP) Setup . (Group 9015-20.) ( 4 ) Program Sensor
Action: Program the pressure sensor on tire that indicated low pressure. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) Does pressure sensor program on tire that indicated low pressure?
Result: YES:Go to Clear Codes and Retest. NO:Replace and program new sensor. See TPM—Tire Pressure Sensor Remove and Install , and See TPM—Programming <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) ( 5 ) Clear Codes and Retest
Action: Clear codes. See CAN monitor unit (CMU)—Codes . (Group 9015-16.) Operate machine for 5 minutes and check codes. Is code 000242.16 still present?
Result: YES:Replace and program new sensor. See TPM—Tire Pressure Sensor Remove and Install , and See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) NO:Checks complete. 000444.04- Invalid App Config 11
Battery voltage below normal or shorted to low source
Invalid App Config Diagnostic Procedure Alarm Level: No Warning Lamp ( 1 ) Intermittent Check
Action: Does diagnostic trouble code (DTC) periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Code Check. ( 2 ) Code Check
Action: Check for active CCU codes. Is CCU code 000639.12 active?
Result: YES:Correct active CCU code 000639.12— See Controller Area Network (CAN) Communication Lost Message . (Group 9001-30.) NO:CCU has incorrect configuration stored. Upload newest software to CCU. Cycle ignition ON and OFF to broadcast configuration to other controllers.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
000619.03- Park Brake Actuator Voltage High 11
The park brake release solenoid A circuit is short to power.
Park Brake Actuator Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Voltage Check. ( 2 ) Voltage Check
Action: →NOTE: All wiring must remain connected. Pull back protective cover to access terminal on park brake relay. Start engine. Check circuit H07 GRN for voltage between pins A and B on park brake release solenoid A (Y46). See Cab Harness (W3) Component Location . (Group 9015-10.) Are 31 volts or more present?
Result: YES:Go to Short Circuit Check. NO:Program chassis control unit (CCU). ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect chassis control unit (CCU) connector (X22) and park brake release solenoid A (Y46). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit H07 GRN for voltage at pin 1 on park brake release solenoid A (Y46) harness connector. Is voltage present?
Result: YES:Circuit H07 GRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connectors (X21, X22, and X23) and park brake release solenoid A (Y46). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 45 (circuit H07 GRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H07 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
000619.05- Park Brake Actuator Current Low 11
The park brake release solenoid A circuit is open.
Park Brake Actuator Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect park brake release solenoid A (Y46). See Cab Harness (W3) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 on park brake release solenoid A (Y46). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-10.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Park brake release solenoid A (Y46) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect chassis control unit (CCU) connector (X22) and park brake release solenoid A (Y46). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H07 GRN for continuity between pin 1 on park brake release solenoid A (Y46) harness connector and pin 45 on CCU connector (X22). Check circuit G41 BLK for continuity between pin 2 on park brake release solenoid A (Y46) harness connector and machine ground. Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuit without continuity indicated is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) ( 4 ) Harness Check
Action: Ignition OFF. <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connector (X22) and park brake release solenoid A (Y46). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 45 (circuit H07 GRN) on CCU connector (X22) and pin 1 on park brake release solenoid A (Y46). Is continuity indicated?
Result: YES:Circuit H07 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
000619.06- Park Brake Actuator Current High 11
The park brake release solenoid A circuit is short to ground.
Park Brake Actuator Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect park brake release solenoid A (Y46). See Cab Harness (W3) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 on park brake release solenoid A (Y46). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-10.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Park brake release solenoid A (Y46) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect chassis control unit (CCU) connector (X22) and park brake release solenoid A (Y46). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H07 GRN for ground at pin 1 on park brake release solenoid A (Y46) harness connector. Is ground present?
Result: YES:Circuit H07 GRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23) and park brake release solenoid A (Y46). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 45 (circuit H07 GRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit H07 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 000628.12- Controller Not Programmed 11
Chassis control unit (CCU) is not programmed. Alarm Level: No Warning Indicator Machine Response: None Additional References: See Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.)
Controller Not Programmed Diagnostic Procedure ( 1 ) Intermittent Check
Action: Does diagnostic trouble code (DTC) periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-15.) NO:Go to Program Controller. ( 2 ) Program Controller
Action: Program CCU. Check for active CCU codes. See Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is code 000628.12 present?
Result: YES:Download latest payload software from software delivery system. NO:Checks complete. 000629.12- Controller Fault 11
The chassis control unit (CCU) timed out from microprocessor error.
Controller Fault Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other CAN communication diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Program chassis control unit (CCU). 000639.12- CAN Lost Message 11
The chassis control unit (CCU) controller area network (CAN) message is lost.
CAN Lost Message Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other CAN communication diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
Action: Ignition OFF. Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.) <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Does CAN circuit test good?
Result: YES: See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Repair CAN circuit. 000639.14- CAN BUS Off 11
The chassis control unit (CCU) CAN BUS is off.
CAN BUS Off Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other CAN communication diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
Action: Ignition OFF. Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES: See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Repair CAN circuit.
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
000880.03- Stop Lamp Circuit Voltage High 11
The stop lamp circuit is short to power.
Stop Lamp Circuit Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Component Check
Action: Ignition OFF. Disconnect right rear park/brake light and left rear park/brake light (E10 and E11). See Rear Lights Harness (W10) Component Location . (Group 9015-10.) Apply 24 volts to pin 3 on brake light assembly, and apply ground at pin 1 of lights (E10 and E11). Do lights illuminate?
Result: YES:Go to Short Circuit Check. NO:Replace light that did not illuminate. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect right rear park/brake light and left rear park/brake light (E10 and E11). See Rear Lights Harness (W10) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit L12 BRN for voltage at pin B on light (E10 or E11) harness connector. Is voltage present?
Result: YES:Circuit L12 BRN is short to power. Repair circuit or replace harness with voltage present. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Lights Harness (W10) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect right rear park/brake light and left rear park/brake light (E10 and E11). See Rear Lights Harness (W10) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 6 (circuit L12 BRN) on CCU connector (X23) and all other pins on connectors (X21, X22, and X23). Is continuity indicated?
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit L12 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Rear Lights Harness (W10) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
000880.04- Stop Lamp Circuit Voltage Low 11
The stop lamp circuit is short to ground.
Stop Lamp Circuit Voltage Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Component Check
Action: Ignition OFF. Disconnect right rear park/brake light and left rear park/brake light (E10 and E11). See Rear Lights Harness (W10) Component Location . (Group 9015-10.) Apply 24 volts to pin 3 on light, and apply ground at pin 1 of lights (E10 and E11). Do lights illuminate?
Result: YES:Go to Short Circuit Check. NO:Replace light that did not illuminate. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect right rear park/brake light and left rear park/brake light (E10 and E11). See Rear Lights Harness (W10) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit L16 BRN for ground at pin B on light (E10 or E11) harness connector. Is voltage present?
Result: YES:Circuit L16 BRN is short to ground. Repair circuit or replace harness with voltage present. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Lights Harness (W10) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect right rear park/brake light and left rear park/brake light (E10 and E11). See Rear Lights Harness (W10) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 6 (circuit L16 BRN) on CCU connector (X23) and all other pins on connectors (X21, X22, and X23). Is continuity indicated?
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit L16 BRN is short to circuit with continuity indicated. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Rear Lights Harness (W10) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
000880.05- Stop Lamp Circuit Current Low 11
The stop lamp circuit is open.
Stop Lamp Circuit Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right rear park/brake light and left rear park/brake light (E10 and E11). See Rear Lights Harness (W10) Component Location . (Group 9015-10.) Apply 24 volts to pin 3 on light, and apply ground at pin 1 of lights (E10 and E11). Do lights illuminate?
Result: YES:Go to Open Circuit Check. NO:Replace light that did not illuminate. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect right rear park/brake light and left rear park/brake light (E10 and E11). See Rear Lights Harness (W10) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L16 BRN for continuity between pin B on light (E10 or E11) harness connector and pin 6 on CCU connector (X23). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit without continuity indicated is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Lights Harness (W10) Wiring Diagram . (Group 9015-10.) 000929.12- Tire Sensor Fault 11
The tire pressure monitoring (TPM) system has a malfunction.
Tire Sensor Fault Diagnostic Procedure Alarm Level: Check Service Code Indicator <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO:Go to Program Sensor. ( 2 ) Program Sensor
Action: Identify tire with malfunction by viewing tire data in the CAN monitor unit (CMU). See CAN monitor unit (CMU)—Machine Options . (Group 9015-16.) Program malfunctioning tire pressure sensor. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) Does tire pressure sensor program?
Result: YES:Clear Codes and Retest. NO:Replace malfunctioning sensor and program new sensor. See TPM—Tire Pressure Sensor Remove and Install . (Group 9015-20.) See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.)
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001045.04- Brake Light Switch Voltage Low 11
The brake light switch circuit is short to ground.
Brake Light Switch Voltage Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect brake switch 4-pin connector (X49). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L21 BRN for ground at pin 2 of service brake light switch (B24) harness connector. Is ground present?
Result: YES:Circuit is short to ground. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect brake switch 4-pin connector (X49). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 23 (circuit L21 BRN) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Replace service brake light switch (B24).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001071.03- Fan Solenoid Voltage High 11
Left side fan speed solenoid high side driver circuit is short to power.
Fan Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect left side fan speed solenoid (Y9). See Engine Harness (W17) Component Location . (Group 9015-10.) Ignition ON. Check circuit H40 GRN for voltage at pin A of left side fan speed solenoid (Y9) harness connector. Is voltage present?
Result: YES:Circuit H40 GRN is short to power. Repair circuit or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Ignition OFF. Disconnect left side fan speed solenoid (Y9). See Engine Harness (W17) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin D4 of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H40 GRN is short to circuit with continuity indicated. Repair or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Code Check. ( 4 ) Code Check
Action: Ignition ON. Is code 001071.03 still present? <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Left side fan speed solenoid (Y9) malfunction. Replace solenoid. See Engine Harness (W17) Component Location . (Group 9015-10.) Program chassis control unit (CCU). NO:Check complete.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001071.05- Fan Solenoid Current Low 11
Left side fan speed solenoid high side driver circuit is open.
Fan Solenoid Current Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left side fan speed solenoid (Y9). See Engine Harness (W17) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Left side fan speed solenoid (Y9) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect left side fan speed solenoid (Y9). See Engine Harness (W17) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H40 GRN for continuity between pin D4 of CCU connector (X21) harness connector and pin A of left side fan speed solenoid (Y9) harness connector. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001071.06- Fan Solenoid Current High 11
Left side fan speed solenoid high side driver circuit is short to ground.
Fan Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left side fan speed solenoid (Y9). See Engine Harness (W17) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Left side fan speed solenoid (Y9) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left side fan speed solenoid (Y9). See Engine Harness (W17) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H40 GRN for ground at pin A on left side fan speed solenoid (Y9) harness connector. Is ground present?
Result: YES:Circuit H40 GRN is short to ground. Repair circuit or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Engine Harness (W17) Component Location . (Group 9015-10.) Disconnect left side fan speed solenoid (Y9). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin D4 (circuit H40 GRN) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit H40 GRN is short to circuit with continuity indicated. Repair or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001071.16- Fan Solenoid Current Moderately High 11
Left side fan speed solenoid low side driver circuit is short to power.
Fan Solenoid Current Moderately High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left side fan speed solenoid (Y9). See Engine Harness (W17) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Left side fan speed solenoid (Y9) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left side fan speed solenoid (Y9). See Engine Harness (W17) Component Location . (Group 9015-10.) Ignition ON. Check circuit R01 BLK for voltage at pin B on left side fan speed solenoid (Y9) harness connector. Is voltage present?
Result: YES:Circuit R01 BLK is short to power. Repair circuit or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Engine Harness (W17) Component Location . (Group 9015-10.) Disconnect left side fan speed solenoid (Y9). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 8 (circuit R01 BLK) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit R01 BLK is short to circuit that indicated continuity. Repair circuit or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001071.17- Fan Solenoid Voltage Slightly Low 11
Left side fan speed solenoid low side driver circuit is open.
Fan Solenoid Voltage Slightly Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left side fan speed solenoid (Y9). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Left side fan speed solenoid (Y9) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect left side fan speed solenoid (Y9). See Engine Interface Harness (W18) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R01 BLK for continuity between pin 8 of CCU connector (X22) harness connector and pin B of left side fan speed solenoid (Y9) harness connector. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Engine Interface Harness (W18) Component Location . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
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Section 9001 page 387
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001071.18- Fan Solenoid Voltage Moderately Low 11
Left side fan speed solenoid low side driver circuit is open.
Fan Solenoid Voltage Moderately Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left side fan speed solenoid (Y9). See Engine Harness (W17) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Left side fan speed solenoid (Y9) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect left side fan speed solenoid (Y9). See Engine Harness (W17) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R01 BLK for continuity between pin 8 of CCU connector (X22) harness connector and pin B of left side fan speed solenoid (Y9) harness connector. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001120.03- Articulation Sensor Voltage High 11
Articulation angle sensor circuit signal is greater than 4.75 volts.
Articulation Sensor Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect articulation angle sensor (B26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Apply 5 volts to pin A and ground to pin B on sensor (B26). Check for voltage at pin C on sensor (B26) while moving sensor through full range of movement. Is return voltage at pin C present and does is it vary with sensor movement?
Result: YES:Go to Open Circuit Check. NO:Replace articulation angle sensor. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect articulation angle sensor (B26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit M13 PUR for continuity between pin 9 of CCU connector (X23) harness connector and pin B of articulation angle sensor (B26) harness connector. Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 4 ) Short Circuit Check
Action: Ignition OFF. Disconnect articulation angle sensor (B26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Ignition ON. Check circuit M13 PUR for voltage at pin B of sensor (B26) harness connector. Is voltage present?
Result: YES:Circuit M13 PUR is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-210.) NO:Go to Harness Check. ( 5 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect articulation angle sensor (B26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Engine Harness (W17) Component Location . (Group 9015-10.) Check for continuity between pin 9 (circuit M13 PUR) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit M13 PUR is short to circuit that indicated continuity. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 390
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001120.04- Articulation Sensor Voltage Low 11
Articulation angle sensor circuit signal is less than 0.25 volts.
Articulation Sensor Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect articulation angle sensor (B26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Apply 5 volts to pin A and ground to pin B on sensor (B26). Check for voltage at pin C on sensor (B26) while moving sensor through full range of movement. Is return voltage at pin C present and does is it vary with sensor movement?
Result: YES:Go to Short Circuit Check. NO:Replace articulation angle sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect articulation angle sensor (B26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit M13 PUR for ground at pin B of sensor (B26) harness connector. Is ground present?
Result: YES:Circuit M13 PUR is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect articulation angle sensor (B26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Engine Harness (W17) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 391
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin 9 (circuit M13 PUR) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit M13 PUR is short to circuit that indicated continuity. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001121.04- EBS Voltage Low 11
The electronic brake switch (EBS) circuit is short to ground.
EBS Voltage Low Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect EBS brake switch (B23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for ground at pin 1 of EBS brake switch (B23). Is continuity indicated?
Result: YES:Electronic brake switch (B23) malfunction. Replace switch. NO:Go to Short Circuit Check. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect EBS brake switch (B23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit M19 PUR for ground at pin 1 of EBS brake switch (B23) connector. Is ground present?
Result: YES:Circuit M19 PUR is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect EBS brake switch (B23). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 12 (circuit M19 PUR) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit M19 PUR is short to circuit with continuity indicated. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001121.12- EBS Brake Switch Bad Device 11
The electronic brake switch (EBS) circuit is short to power or malfunctioning.
EBS Brake Switch Bad Device Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect EBS brake switch (B23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pins 1 and 4 on EBS brake switch (B23). Is continuity indicated?
Result: YES:Electronic brake switch (B23) malfunction. Replace switch. NO:Go to Short Circuit Check. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect EBS brake switch (B23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit M19 PUR for voltage at pin 1 of EBS brake switch (B23) connector. Is voltage present?
Result: YES:Circuit M19 PUR is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect EBS brake switch (B23). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 12 (circuit M19 PUR) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit M19 PUR is short to circuit with continuity indicated. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 001231.12- CAN 2 Lost Message 11
The chassis control unit (CCU) controller area network (CAN) 2 message is lost.
CAN 2 Lost Message Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other CAN communication diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to CAN Circuit Check. ( 2 ) CAN Circuit Check
Action: Ignition OFF. Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES: See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Repair CAN circuit. 001231.14- CAN BUS Off 11
The chassis control unit (CCU) CAN BUS is off.
CAN BUS Off Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other CAN communication diagnostic trouble codes present?
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to CAN Circuit Check. ( 2 ) CAN Circuit Check
Action: Ignition OFF. Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES: See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Repair CAN circuit. 001547.04- Air Conditioning Thermal Switch Voltage Low 11
The air conditioner freeze control switch circuit is short to ground.
Air Conditioning Thermal Switch Voltage Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Switch Check
Action: Disconnect freeze control switch (B28). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Check for ground at freeze control switch (B28). Is ground present?
Result: YES:Freeze control switch (B28) malfunction. Replace switch. NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for ground at pin 27 (circuit A28 ORG) of CCU connector (X23). Is ground present?
Result: YES:Circuit A28 ORG is short to ground. Repair or replace harness. See Air Conditioner Unit Harness (W16) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 397
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001550.03- Air Conditioning Clutch Voltage High 11
The air conditioner compressor clutch circuit is short to power.
Air Conditioning Clutch Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Disconnect air conditioner compressor clutch (Y22). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check for power on circuit J01 TAN at air conditioner compressor clutch (Y22) harness connector. Is power measured?
Result: YES:Circuit J01 TAN is short to power. Repair or replace harness. See Front Frame Harness (W2) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect air conditioner compressor clutch (Y22). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 10 (circuit A31 ORG) of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit A31 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Front Frame Harness (W2) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 398
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001550.05- Air Conditioning Clutch Current Low 11
The air conditioner compressor clutch circuit is open.
Air Conditioning Clutch Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check—Pressure Switch. ( 2 ) Component Check—Pressure Switch
Action: Ignition OFF. Disconnect and test the air conditioner high/low-pressure switch (B27). See Air Conditioner High/Low-Pressure Switch Test . (Group 9031-25.) Does the high/low-pressure switch test good?
Result: YES:Go to Open Circuit Check. NO:Air conditioner high/low-pressure switch (B27) malfunction. Replace switch. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect air conditioner compressor clutch (Y22) and air conditioner high/low-pressure switch (B27). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A31 ORG for continuity between pin A on air conditioner high/low-pressure switch (B27) harness connector and pin 10 on (CCU) connector (X22). Check circuit J01 TAN for continuity between pin B on air conditioner high/low-pressure switch (B27) and pin on air conditioner compressor clutch (Y22) harness connector. Is continuity indicated?
Result: YES:Go to Code Check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Front Frame Harness (W2) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) ( 4 ) Code Check
Action: Ignition ON. Is code 001550.06 still present? <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Air conditioner compressor clutch (Y22) malfunction. Replace clutch. See Front Frame Harness (W2) Component Location . (Group 9015-10.) Program chassis control unit (CCU). NO:Check complete.
<- Go to Section TOC
Section 9001 page 400
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001550.06- Air Conditioning Clutch Current High 11
The air conditioner compressor clutch circuit is short to ground.
Air Conditioning Clutch Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check—Compressor Clutch. ( 2 ) Component Check—Compressor Clutch
Action: Ignition OFF. Disconnect air conditioner compressor clutch (Y22). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance between terminals on air conditioner compressor clutch (Y22). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Component Check—Pressure Switch. NO:Air conditioner compressor clutch (Y22) malfunction. Replace clutch. ( 3 ) Component Check—Pressure Switch
Action: Ignition OFF. Disconnect and test the air conditioner high/low pressure switch (B27). See Air Conditioner High/Low-Pressure Switch Test (Group 9031-25.) Does the high/low pressure switch test good?
Result: YES:Go to Short Circuit Check. NO:Air conditioner high/low pressure switch (B27) malfunction. Replace switch. ( 4 ) Short Circuit Check
Action: Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for ground at pin 10 (circuit A31 ORG) of CCU connector (X22). Is ground present?
<- Go to Section TOC
Section 9001 page 401
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit is short to ground. Repair or replace harness. See Front Frame Harness (W2) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Go to Harness Check. ( 5 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect air conditioner compressor clutch (Y22). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 10 (circuit A31 ORG) of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit A31 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Front Frame Harness (W2) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 402
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001638.00- Hydraulic Oil Temperature Very High 11
The hydraulic oil temperature is above 110°C (230°F).
Hydraulic Temperature Very High Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Hydraulic Oil Temperature Sensor Check. ( 2 ) Hydraulic Oil Temperature Sensor Check
Action: Ignition OFF. Disconnect hydraulic temperature sensor (B54). See Hydraulic Tank Harness (W8) Component Location . (Group 9015-10.) Measure resistance across pins A and B on hydraulic temperature sensor (B54). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Hydraulic Oil Temperature Check. NO:Hydraulic temperature sensor (B54) malfunction. Replace sensor. ( 3 ) Hydraulic Oil Temperature Check
Action: Check hydraulic oil temperature on the monitor. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Is oil temperature above 93°C (199°F)?
Result: YES: See Hydraulic Oil Overheats . (Group 9015-15.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 403
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001638.03- Hydraulic Oil Temperature Sensor Voltage High 11
The hydraulic oil temperature sensor signal circuit is greater than 4.886 volts.
Hydraulic Oil Temperature Sensor Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect hydraulic temperature sensor (B54). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Measure resistance across pins on hydraulic temperature sensor (B54). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Hydraulic temperature sensor (B54) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect hydraulic temperature sensor (B54). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit X07 YEL for voltage at pin A on hydraulic temperature sensor (B54) harness. Is voltage present?
Result: YES:Circuit X07 YEL is short to power. Repair circuit or replace harness. See Hydraulic Harness (W9) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Go to Open Circuit Check. ( 4 ) Open Circuit Check
Action: Ignition OFF. Disconnect hydraulic temperature sensor (B54). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 404
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check circuit X07 YEL for continuity between hydraulic temperature sensor (B54) harness and pin 51 on (CCU) connector (X23). Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Hydraulic Harness (W9) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) ( 5 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect hydraulic temperature sensor (B54). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 51 (circuit X07 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Hydraulic Harness (W9) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 405
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001638.04- Hydraulic Oil Temperature Sensor Voltage Low 11
The hydraulic oil temperature sensor signal circuit is near 0 volts.
Hydraulic Oil Temperature Sensor Voltage Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect hydraulic temperature sensor (B54). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Measure resistance across pins on hydraulic temperature sensor (B54). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Hydraulic temperature sensor (B54) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect hydraulic temperature sensor (B54). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit X07 YEL for ground at pin A on hydraulic temperature sensor (B54) harness. Is voltage present?
Result: YES:Circuit X07 YEL is short to ground. Repair circuit or replace harness. See Hydraulic Harness (W9) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect hydraulic temperature sensor (B54). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 406
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin 51 (circuit X07 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Repair circuit with continuity indicated to another circuit or replace harness. See Hydraulic Harness (W9) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Program chassis control unit (CCU). 001639.00- Fan Speed High 11
The left fan speed is faster than commanded speed.
Fan Speed High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other hydraulic fan diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to Component Check. ( 3 ) Component Check
Action: Ignition OFF. Disconnect left fan speed sensor (B7). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance across pins A and B on left fan speed sensor (B7). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Program chassis control unit (CCU). NO:Left side fan speed sensor malfunction. Replace sensor. 001639.01- Fan Speed Low 11
The left hydraulic fan speed is slower than commanded speed. <- Go to Section TOC
Section 9001 page 407
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Fan Speed Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other hydraulic fan diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to Component Check. ( 3 ) Component Check
Action: Ignition OFF. Disconnect left fan speed sensor (B7). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance across pins A and B on left fan speed sensor (B7). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Program chassis control unit (CCU). NO:Left fan speed sensor malfunction. Replace sensor.
<- Go to Section TOC
Section 9001 page 408
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001639.08- Fan Speed Sensor Bad Freq Data 11
The left side fan speed is not measured with fan moving.
Fan Speed Sensor Bad Freq Data Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 005562.08 present?
Result: YES: Go to Open Circuit Check . NO:Go to Component Check. ( 3 ) Component Check
Action: Ignition OFF. Disconnect left side fan speed sensor (B7). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance across pins A and B on left side fan speed sensor (B7). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Replace left side fan speed sensor. ( 4 ) Open Circuit Check
Action: Ignition OFF. Disconnect chassis control unit (CCU) connector (X21). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect cab harness-to-front frame harness 21-pin connector (X14). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check circuit P50 RED for continuity between pin M on connector (X14) and pin E1 on CCU connector harness (X21). Is continuity indicated?
<- Go to Section TOC
Section 9001 page 409
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Go to next check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.)
Action: Check circuit R51 BLK for continuity between pin L on connector (X14) and pin F1 on CCU connector harness (X21). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.)
Action: Disconnect left side fan speed sensor (B7). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check circuit P50 RED for continuity between pin M on connector (X14) and pin A on speed sensor (B7). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.)
Action: Check circuit R51 BLK for continuity between pin L on connector (X14) and pin B on speed sensor (B7). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.)
Action: Check circuit M20 PUR for continuity between pin C on left side fan speed sensor (B7) and pin 27 on CCU connector (X22). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) 001697.04- Tire Sensor Batteries Low 11
The tire pressure monitoring (TPM) system sensor batteries are low.
Tire Sensor Batteries Low Diagnostic Procedure Alarm Level: Check Service Code Indicator <- Go to Section TOC
Section 9001 page 410
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Pressure Check
Action: Ignition ON. Identify tire with low sensor battery level using the CAN monitor unit (CMU). See CAN monitor unit (CMU)—Machine Options . (Group 9015-16.) Check battery voltage on specified sensor. Is battery voltage low on specified sensor?
Result: YES:Replace low battery and program sensor. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) NO:Go to Clear Codes and Retest. ( 2 ) Clear Codes and Retest
Action: Clear codes. See CAN monitor unit (CMU)—Codes . (Group 9015-16.) Operate machine for 5 minutes and check codes. Is code 001697.04 still present?
Result: YES:Replace malfunctioning sensor and program new sensor. See TPM—Tire Pressure Sensor Remove and Install , and See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) NO:Checks complete. 001713.01- Hydraulic Oil Filter Pressure Very Low 11
The hydraulic oil filter restriction switch is open with engine running and hydraulic oil temperature is above 35°C (95°F).
Hydraulic Oil Filter Pressure Very Low Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the hydraulic oil filter restriction switch (B9). See Hydraulic Harness (W13) Component Location . (Group 9015-10.) Check for continuity between pins 1 and 2 on restriction switch (B9). <- Go to Section TOC
Section 9001 page 411
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Go to Hydraulic Oil Filter Check. NO:Hydraulic oil filter restriction switch (B9) malfunction. Replace switch. ( 3 ) Hydraulic Oil Filter Check
Action: Remove hydraulic oil filter. See Hydraulic System Component Location . (Group 9025-15.) Is filter clogged with excessive debris?
Result: YES:Replace filter. See Replace Hydraulic System Return Filter . (Operator′s Manual.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 412
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
001713.03- Hydraulic Oil Filter Voltage High 190
The hydraulic oil filter restriction switch signal is greater than 3.9 volts.
Hydraulic Oil Filter Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Disconnect hydraulic oil filter restriction switch (B9). See Hydraulic Harness (W13) Component Location . (Group 9015-10.) Ignition ON. Check circuit N10 YEL for voltage at pin 2 on restriction switch (B9) connector. Is voltage present?
Result: YES:Circuit N10 YEL is short to power. Repair circuit or replace harness. See Hydraulic Harness (W13) Wiring Diagram See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect hydraulic oil filter restriction switch (B9). See Hydraulic Harness (W13) Component Location . (Group 9015-10.) Disconnect CCU connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 11 (circuit N10 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit N10 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Hydraulic Harness (W13) Wiring Diagram. (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 001713.16- Hydraulic Oil Filter Stuck Open 11
The hydraulic oil filter restriction switch is open with engine running and hydraulic oil temperature is below or equal to 35°C (95°F).
Hydraulic Oil Filter Stuck Open Diagnostic Procedure Alarm Level: <- Go to Section TOC
Section 9001 page 413
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the hydraulic oil filter restriction switch (B9). See Hydraulic Harness (W13) Component Location . (Group 9015-10.) Check for continuity between pins 1 and 2 on restriction switch (B9). Is continuity indicated?
Result: YES:Problem intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Hydraulic oil filter restriction switch (B9) malfunction. Replace switch.
<- Go to Section TOC
Section 9001 page 414
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002000.09- ECU CAN Comm Bad Update Rate 11
CAN communication error; the chassis control unit (CCU) has lost communication with the engine control unit (ECU).
ECU CAN Comm Bad Update Rate Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to ECU Sensor Check. ( 2 ) ECU Sensor Check
Action: Turn battery disconnect to OFF. Wait 5 seconds and turn battery disconnect to ON. View engine control unit (ECU) monitored sensor outputs, by accessing the Diagnostics / Engine Sensors submenu on the CAN monitor unit (CMU). See CAN monitor unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Are all engine sensor values displayed on the CMU?
Result: YES:Program engine control unit (ECU). NO:Go to Fuse Check. ( 3 ) Fuse Check
Action: Ignition OFF. Remove fuses (F14 and F28). See Fuse and Relay Specifications . (Group 9015-10.) Check fuses (F14 and F28) for continuity. Is continuity indicated?
Result: YES:Go to Voltage Check. NO:Replace fuses without continuity indicated. ( 4 ) Voltage Check
Action: Ignition OFF. Disconnect ECU connector (X13). See Engine Harness (W17) Component Location . (Group 9015-10.) Ignition ON. Check for voltage at the following pins on ECU connector (X13): 7—circuit P24 RED 13—circuit P09 RED 14—circuit P09 RED <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
23—circuit P09 RED 24—circuit P09 RED Is voltage indicated?
Result: YES:Go to Ground Circuit Check. NO:Circuit that does not indicate voltage is open. Repair circuit or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 5 ) Ground Circuit Check
Action: Ignition OFF. Disconnect ECU connector (X13). See Engine Harness (W17) Component Location . (Group 9015-10.) Check for ground at the following pins on ECU connector (X13): 27—G17 BLK 43—G17 BLK 44—G17 BLK Is ground present?
Result: YES:Go to CAN Circuit Check. NO:Circuit that does not indicate ground is open. Repair circuit or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) ( 6 ) CAN Circuit Check
Action: Ignition OFF. Test CAN circuit. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program transmission control unit (TCU). NO:Repair CAN circuit.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002003.09- TCU CAN Comm Bad Update Rate 11
CAN communication error; the chassis control unit (CCU) has lost communication with the transmission control unit (TCU).
TCU CAN Comm Bad Update Rate Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to TCU Sensor Check. ( 2 ) TCU Sensor Check
Action: Turn battery disconnect to OFF. Wait 5 seconds and turn battery disconnect to ON. View transmission control unit (TCU) monitored sensor outputs, by accessing the Diagnostics / Transmission Sensors submenu on the CAN monitor unit (CMU). See CAN monitor unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Are all transmission sensor values displayed on the CMU?
Result: YES:Program chassis control unit (CCU). NO:Go to Fuse Check. ( 3 ) Fuse Check
Action: Ignition OFF. Disconnect fuses (F11 and F25). See Fuse and Relay Specifications . (Group 9015-10.) Check fuses (F11 and F25) for continuity. Is continuity indicated?
Result: YES:Go to Voltage Check. NO:Replace fuses without continuity indicated. ( 4 ) Voltage Check
Action: Ignition OFF. Disconnect transmission control unit (TCU) connector (X51). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Ignition ON. Check circuit P35 RED for voltage at pin 8 on TCU connector (X51). Check circuit P37 RED for voltage at pins 2 and 5 on TCU connector (X51). Is system voltage (approximately 24 volts) present at all pins? <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Go to Ground Circuit Check. NO:Circuits without voltage are open. Repair circuits or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) ( 5 ) Ground Circuit Check
Action: Ignition OFF. Disconnect transmission control unit (TCU) connector (X51). See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check circuit G12 BLK for ground at pins 1 and 4 on TCU harness connector (X51). Is ground present?
Result: YES:Go to CAN Circuit Check. NO:Circuit that did not indicate ground is open. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) ( 6 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Replace the transmission control unit (TCU). NO:Repair CAN circuit.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002023.09- CMU CAN Comm Bad Update Rate 11
CAN communication error; the chassis control unit (CCU) has lost communication with the CAN monitor unit (CMU).
CMU CAN Comm Bad Update Rate Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to CMU Sensor Check. ( 2 ) CMU Sensor Check
Action: Turn battery disconnect to OFF. Wait 5 seconds and turn battery disconnect to ON. View CAN monitor unit (CMU) monitored sensor outputs, by accessing the Diagnostics / EH Sensors submenu on the CMU. See CAN monitor unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Are all sensor values displayed on the CMU?
Result: YES:Program chassis control unit (CCU). NO:Go to Fuse Check. ( 3 ) Fuse Check
Action: Ignition OFF. Disconnect fuses (F8 and F22). See Fuse and Relay Specifications . (Group 9015-10.) Check fuses (F8 and F22) for continuity. Is continuity indicated?
Result: YES:Go to Voltage Check. NO:Replace fuse (F8 or F22). ( 4 ) Voltage Check
Action: Ignition OFF. Disconnect CAN monitor unit (CMU). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check for voltage at pins A and L on the CMU connector. Is system voltage present at both pins?
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Go to Ground Circuit Check. NO:Circuits without voltage are open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 5 ) Ground Circuit Check
Action: Ignition OFF. Disconnect the CAN monitor unit (CMU) connector. See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit G37 BLK for ground at pin P on the CMU connector. Is ground present at all pins?
Result: YES:Go to CAN Circuit Check. NO:Circuit that does not indicate ground is open. Repair circuit or replace harness. See Cab Harness (W3) Component Location . (Group 9015-10.) ( 6 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program CAN monitor unit (CMU). NO:Repair CAN circuit.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002051.09- TPM CAN Comm Bad Update Rate 11
CAN communication error; the chassis control unit (CCU) has lost communication with the tire pressure monitor (TPM).
TPM CAN Comm Bad Update Rate Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to TPM Sensor Check. ( 2 ) TPM Sensor Check
Action: Turn battery disconnect to OFF. Wait 5 seconds and turn battery disconnect to ON. View transmission control unit (TCU) monitored sensor outputs, by accessing the Diagnostics / Transmission Sensors submenu on the CAN monitor unit (CMU). See CAN monitor unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Are all transmission sensor values displayed on the CMU?
Result: YES:Program chassis control unit (CCU). NO:Go to Fuse Check. ( 3 ) Fuse Check
Action: Ignition OFF. Disconnect fuse (F24). See Fuse and Relay Specifications . (Group 9015-10.) Check fuse (F24) for continuity. Is continuity indicated?
Result: YES:Go to Voltage Check. NO:Replace fuse (F24). ( 4 ) Voltage Check
Action: Ignition OFF. Disconnect tire pressure monitor (TPM) system connector. See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Ignition ON. Check circuit P20 RED for voltage at pin 2 on TPM connector. Is system voltage (approximately 24 volts) present?
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Go to Ground Circuit Check. NO:Circuit that does not indicate voltage is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) ( 5 ) Ground Circuit Check
Action: Ignition OFF. Disconnect tire pressure monitor (TPM) system connector. See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check circuit G11 BLK for ground at pin 1 on TPM harness connector. Is ground present?
Result: YES:Go to CAN Circuit Check. NO:Circuit that does not indicate ground is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) ( 6 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program tire pressure monitor (TPM) system controller. NO:Repair CAN circuit.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002064.09- OBW CAN Comm Bad Update Rate 11
CAN communication error; the chassis control unit (CCU) has lost communication with the on board weighing (OBW) controller.
OBW CAN Comm Bad Update Rate Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) OBW Sensor Check
Action: Turn battery disconnect to OFF. Wait 5 seconds and turn battery disconnect to ON. Check onboard weighing (OBW) inputs by accessing the OBW readings menu on the CAN monitor unit. See CAN Monitor Unit (CMU)—OBW Readings . (Group 9015-16.) Are onboard weighing values displayed on the CMU?
Result: YES:Program chassis control unit (CCU). NO:Go to Fuse Check. ( 2 ) Fuse Check
Action: Remove fuse (F24). See Fuse and Relay Specifications . (Group 9015-10.) Check fuse (F24) for continuity. Is continuity indicated?
Result: YES:Go to Voltage Check. NO:Fuse (F24) is blown. Replace fuse. ( 3 ) Voltage Check
Action: Ignition OFF. Disconnect onboard weighing (OBW) controller (A18) connector. See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Ignition ON. Check circuit P20 RED for voltage at pin 4 on OBW controller connector. Is system voltage (approximately 24 volts) present?
Result: YES:Go to Ground Circuit Check. NO:Circuit P20 RED is open. Repair wire or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) ( 4 ) Ground Circuit Check
Action: Ignition OFF. <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect onboard weighing (OBW) controller (A18) connector. See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check circuit G11 BLK for ground at pin 3 on OBW controller harness connector. Is ground present?
Result: YES:Circuit G11 BLK is open. Repair circuit or replace harness. See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Go to CAN Circuit Check. ( 5 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program or Replace onboard weighing (OBW) controller. NO:Repair CAN circuit. 002140.09- OC3 CAN Comm Bad Update Rate 11
CAN communication error; the chassis control unit (CCU) has lost communication with the 25-button sealed switch module (SSM) (OC3).
OC3 CAN Comm Bad Update Rate Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to OC3 Sensor Check. ( 2 ) OC3 Sensor Check
Action: Turn battery disconnect to OFF. Wait 5 seconds and turn battery disconnect to ON. Ignition ON. Activate windshield wiper function by pushing button on the 25-button SSM (OC3). Do windshield wipers function?
Result: YES:Program chassis control unit (CCU). NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Replace the 25-button SSM (OC3). NO:Repair CAN circuit.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002141.09- OC4 CAN Comm Bad Update Rate 11
CAN communication error; the chassis control unit (CCU) has lost communication with the 15-button sealed switch module (SSM) (OC4).
OC4 CAN Comm Bad Update Rate Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to OC4 Sensor Check. ( 2 ) OC4 Sensor Check
Action: Turn battery disconnect to OFF. Wait 5 seconds and turn battery disconnect to ON. Ignition ON. Activate blower motor function on 15-button SSM (OC4). Does the blower motor function properly?
Result: YES:Program chassis control unit (CCU). NO:Go to Fuse Check. ( 3 ) Fuse Check
Action: Ignition OFF. Disconnect fuse (F22). See Fuse and Relay Specifications . (Group 9015-10.) Check fuse (F22) for continuity. Is continuity indicated?
Result: YES:Go to Voltage Check. NO:Replace fuse (F22) without continuity indicated. ( 4 ) Voltage Check
Action: Ignition OFF. Disconnect 15-button sealed switch module (SSM) (OC4) connector. See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit P67 RED for voltage at pin 1 on 15-button SSM (OC4) connector. Is system voltage (approximately 24 volts) present? <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Go to Ground Circuit Check. NO:Circuit that does not indicate voltage is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 5 ) Ground Circuit Check
Action: Ignition OFF. Disconnect 15-button SSM (OC4) connector. See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit G05 BLK for ground at pin 2 on 15-button SSM (OC4) harness connector. Is ground present?
Result: YES:Go to CAN Circuit Check. NO:Circuit that does not indicate ground is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 6 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Replace the transmission control unit (TCU). NO:Repair CAN circuit.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002251.09- JDL CAN Comm Bad Update Rate 11
CAN communication error; the chassis control unit (CCU) has lost communication with the modular telematics gateway (MTG).
JDL CAN Comm Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Fuse Check. ( 2 ) Fuse Check
Action: Ignition OFF. Disconnect fuses (F13 and F27). See Fuse and Relay Specifications . (Group 9015-10.) Check fuses (F13 and F27) for continuity. Is continuity indicated?
Result: YES:Go to Voltage Check. NO:Replace fuse without continuity indicated. ( 3 ) Voltage Check
Action: Ignition OFF. Disconnect modular telematics gateway (MTG) connector (X6014). See JDLink™ Harnesses (W6002 and W6003) Component Location . (Group 9015-10.) Ignition ON. Check circuit P84 RED for voltage at pin 1 on connector (X6014). Check circuit P85 RED for voltage at pin 2 on connector (X6014). Is system voltage (approximately 24 volts) present?
Result: YES:Go to Ground Circuit Check. NO:Circuit that did not indicate voltage is open. Repair circuit or replace harness. See JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram . (Group 9015-10.) ( 4 ) Ground Circuit Check
Action: Ignition OFF. Disconnect modular telematics gateway (MTG) connector (X6014). See JDLink™ Harnesses (W6002 and W6003) Component Location . (Group 9015-10.) <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check circuit G10 BLK for ground at pin M1 on connector (X6014). Is ground present?
Result: YES:Go to CAN Circuit Check. NO:Circuit that did not indicate ground is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 5 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Replace the modular telematics gateway (MTG) controller. NO:Repair CAN circuit.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002347.04- Hi Beam Headlight Switch Voltage Low 11
The high beam headlight switch circuit is open.
Hi Beam Headlight Switch Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect steering column switch (S2). See Cab Harness (W3) Component Location . (Group 9015-10.) Check steering column switch (S2). See Steering Column Switch Test . (Group 9015-20.) Does switch test good?
Result: YES:Go to Open Circuit Check. NO:Replace light that does not come on. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect steering column switch (S2). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 5 (circuit L22 BRN) of steering column switch (S2) harness connector and pin 36 of CCU connector (X23). Check for continuity between pin 3 (circuit L18 BRN) of steering column switch (S2) harness connector and pin 13 of CCU connector (X23). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuits without continuity are open. Repair circuits or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.)
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002348.03- Hi Beam Headlight Voltage High 11
The high beam headlight high side driver circuit is short to power.
Hi Beam Headlight Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check for voltage at pin 3 (circuit L06 BRN) of CCU connector (X22). Is voltage present?
Result: YES:Circuit with voltage present is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 3 (circuit L06 BRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L06 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002348.05- Hi Beam Headlight Current Low 11
The high beam headlight high side driver circuit is open.
Hi Beam Headlight Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right high beam headlight (E5) and left high beam headlight (E8). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Apply 24 volts to pin 1 and ground to pin 2 on malfunctioning headlight (E5 or E8). Do lights come on?
Result: YES:Go to Open Circuit Check. NO:Replace headlight that does not come on. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect right high beam headlight (E5) and left high beam headlight (E8). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L06 BRN for continuity between pin 1 of right or left high beam headlight (E5 and E8) harness connectors and pin 3 on CCU connector (X22). Check circuit G30 BLK for continuity between pin 2 of right high beam headlight (E5) harness connectors and frame ground. Check circuit G32 BLK for continuity between pin 2 of left high beam headlight (E8) harness connectors and frame ground. Is continuity present?
Result: YES:Program chassis control unit. NO:Circuits that do not indicate continuity are open. Repair circuits or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002348.06- Hi Beam Headlight Current High 11
The high beam headlight high side driver circuit is short to ground.
Hi Beam Headlight Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right high beam headlight (E5) and left high beam headilght (E8). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Check for ground between pin 1 of malfunctioning headlight (E5 or E8) and machine ground. Is ground present?
Result: YES:Light is internally short to ground. Replace light. NO:Go to Short Circuit Check. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right high beam headlight (E5) and left high beam headlight (E8). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check for ground at pin 3 (circuit L06 BRN) of CCU connector (X22). Is ground present?
Result: YES:Circuit is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
9015-10.) Check for continuity between pin 3 (circuit L06 BRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L06 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002350.03- Lo Beam Headlight Voltage High 11
The low beam headlight high side driver circuit is short to power.
Lo Beam Headlight Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect right low beam headlight (E4) and left low beam headlight (E7). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check for voltage at pin 6 (circuit L13 BRN) of CCU connector (X22). Is voltage present?
Result: YES:Circuit L13 BRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect right low beam headlight (E4) and left low beam headlight (E7). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 6 (circuit L13 BRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L13 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 435
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002350.05- Lo Beam Headlight Current Low 11
The low beam headlight high side driver circuit is open.
Lo Beam Headlight Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right low beam headlight (E4) and left low beam headlight (E7). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Apply 24 volts to pin 1 and ground to pin 2 on malfunctioning headlight (E4 or E7). Do lights come on?
Result: YES:Go to Open Circuit Check. NO:Replace headlight that does not come on. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect right low beam headlight (E4) and left low beam headlight (E7). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L13 BRN for continuity between pin 1 of right or left low beam headlight (E4 or E7) harness connectors and pin 6 on CCU connector (X22). Check circuit G29 BLK for continuity between pin 2 of right low beam headlight (E4) harness connectors and frame ground. Check circuit G33 BLK for continuity between pin 2 of left low beam headlight (E7) harness connectors and frame ground. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuits that do not indicate continuity are open. Repair circuits or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 436
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002350.06- Lo Beam Headlight Current High 11
The low beam headlight high side driver circuit is short to ground.
Lo Beam Headlight Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right low beam headlight (E4) and left low beam headlight (E7). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Apply 24 volts to pin 1 and ground to pin 2 on malfunctioning headlight (E4 or E7). Do lights come on?
Result: YES:Go to Short Circuit Check. NO:Replace light that does not come on. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right low beam headlight (E4) and left low beam headlight (E7). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L13 BRN for ground at pin 1 of right and left low beam headlights (E4 and E7) harness connectors. Is ground present?
Result: YES:Circuit L13 BRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect right low beam headlight (E4) and left low beam headlight (E4). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 437
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 6 (circuit L13 BRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L13 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 438
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002355.03- Work Lights Voltage High 11
The work lights high side driver circuit is short to power.
Work Lights Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect left work light (E28) and right work light (E29). See Front Work Lights Harness (W13) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit L14 BRN for voltage at pin 1 of left and right work lights (E28 and E29) harness connectors. Is voltage present?
Result: YES:Circuit L14 BRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Work Lights Harness (W13) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect left work light (E28) and right work light (E29). See Front Work Lights Harness (W13) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 6 (circuit L14 BRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L14 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Work Lights Harness (W13) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 439
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002355.05- Work Lights Current Low 11
The work lights high side driver circuit is open.
Work Lights Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left work light (E28) and right work light (E29). See Front Work Lights Harness (W13) Component Location . (Group 9015-10.) Apply 24 volts to pin 1 and ground to pin 2 on malfunctioning light (E28 or E29). Do lights come on?
Result: YES:Go to Open Circuit Check. NO:Replace light that does not come on. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect left work light (E28) and right work light (E29). See Front Work Lights Harness (W13) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L14 BRN for continuity between pin 1 on right and left work lights (E28 and E29) harness connectors and pin 18 on CCU connector harness (X22). Check circuit G34 BLK or continuity between pin 2 on right and left work lights (E28 and E29) harness connector and machine ground. Is continuity indicated?
Result: YES:Program chassis control unit. NO:Circuits that do not indicate continuity are open. Repair circuits or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Work Lights Harness (W13) Wiring Diagram . (Group 9015-10.)
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Section 9001 page 440
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002355.06- Work Lights Voltage Low 11
The work lights high side driver circuit is short to ground.
Work Lights Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left work light (E28) and right work light (E29). See Front Work Lights Harness (W13) Component Location . (Group 9015-10.) Apply 24 volts to pin 1 and ground to pin 2 on malfunctioning light (E28 or E29). Do lights come on?
Result: YES:Go to Short Circuit Check. NO:Replace light that does not come on. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left work light (E28) and right work light (E29). See Front Work Lights Harness (W13) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L14 BRN for ground at pin 1 of right and left work lights (E28 and E29) harness connectors. Is ground present?
Result: YES:Circuit L14 BRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Work Lights Harness (W13) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect left work light (E28) and right work light (E29). See Front Work Lights Harness (W13) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 441
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 18 (circuit L14 BRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L14 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Work Lights Harness (W13) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 442
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002368.03- Left Turn Signal Voltage High 11
The left turn signal high side driver circuit is short to power.
Left Turn Signal Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect left rear turn light (E2) and left front turn light (E6). See Front Frame Harness (W2) Wiring Diagram and See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L19 BRN for voltage at pin 3 of left rear turn light (E2) harness connector. Check circuit L19 BRN for voltage at pin 1 of left front turn light (E6) harness connector. Is voltage present?
Result: YES:Circuit L19 BRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect left rear turn light (E2) and left front turn light (E6). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 18 (circuit L19 BRN) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L19 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). <- Go to Section TOC
Section 9001 page 443
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
<- Go to Section TOC
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Section 9001 page 444
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002368.05- Left Turn Signal Current Low 11
The left turn signal high side driver circuit is open.
Left Turn Signal Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left rear turn light (E2) and left front turn light (E6). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Apply 24 volts to pin 3 and ground to pin 1 of left rear turn light (E2). Apply 24 volts to pin 1 and ground to pin 2 of left front turn light (E6). Do lights come on?
Result: YES:Go to Open Circuit Check. NO:Replace light that does not come on. ( 3 ) Open Circuit Check
Action: Turn battery disconnect switch OFF. Disconnect left rear turn light (E2) and left front turn light (E6). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L19 BRN for continuity between pin 18 on CCU connector (X23) and pin 3 on left rear turn light (E2). Check circuit G11 BLK for continuity between pin 1 of left rear turn light (E2) and machine ground. Check circuit L19 BRN for continuity between pin 18 on CCU connector (X23) and pin 1 of left front turn light (E6). Check circuit G35 BLK for continuity between pin 2 of left front turn light (E6) and machine ground. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuits or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 445
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002368.06- Left Turn Signal Current High 11
The left turn signal high side driver circuit is short to ground.
Left Turn Signal Current High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left rear turn light (E2) and left front turn light (E6). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Apply 24 volts to pin 3 and ground to pin 1 of left rear turn light (E2). Apply 24 volts to pin 1 and ground to pin 2 of left front turn light (E6). Do lights come on?
Result: YES:Go to Short Circuit Check. NO:Replace light that does not come on. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left rear turn light (E2) and left front turn light (E6). See Front Frame Harness (W2) Wiring Diagram and See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check circuit L19 BRN for ground at pin 3 of left rear turn light (E2) harness connector. Check circuit L19 BRN for ground at pin 1 of left front turn light (E6) harness connector. Is voltage present?
Result: YES:Circuit L19 BRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. <- Go to Section TOC
Section 9001 page 446
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect left rear turn light (E2) and left front turn light (E6). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 18 (circuit L19 BRN) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L19 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 447
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002370.03- Right Turn Signal Voltage High 11
The right turn signal high side driver circuit is short to power.
Right Turn Signal Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect right rear turn light (E1) and right front turn light (E3). See Front Frame Harness (W2) Wiring Diagram and See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit L10 BRN for voltage at pin 3 of right rear turn signal (E1) harness connector. Check circuit L10 BRN for voltage at pin 1 of right front turn signal (E3) harness connector. Is voltage present?
Result: YES:Circuit L10 BRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect right rear turn light (E1) and right front turn light (E3). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 42 (circuit L10 BRN) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L10 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 448
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 449
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002370.05- Right Turn Signal Current Low 11
The right turn signal high side driver circuit is open.
Right Turn Signal Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right rear turn light (E1) and right front turn light (E3). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Apply 24 volts to pin 3 and ground to pin 1 of right rear turn light (E1). Apply 24 volts to pin 1 and ground to pin 2 of right front turn light (E3). Do lights come on?
Result: YES:Go to Open Circuit Check. NO:Replace light that does not come on. ( 3 ) Open Circuit Check
Action: Turn battery disconnect switch OFF. Disconnect right rear turn light (E1) and right front turn light (E3). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L10 BRN for continuity between pin 3 on right rear turn light (E1) and pin 42 on CCU connector (X23). Check circuit G11 BLK for continuity between pin 1 on right rear turn light (E1) and machine ground. Check circuit L10 BRN for continuity between pin 1 on right front turn light (E3) and pin 42 on CCU connector (X23). Check circuit G15 BLK for continuity between pin 2 on right front turn light (E1) and machine ground. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 450
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002370.06- Right Turn Signal Current High 11
The right turn signal circuit is high side driver short to ground.
Right Turn Signal Current High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right rear turn light (E1) and right front turn light (E3). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Apply 24 volts to pin 3 and ground to pin 1 of right rear turn light (E1). Apply 24 volts to pin 1 and ground to pin 2 of right front turn light (E3). Do lights come on?
Result: YES:Go to Short Circuit Check. NO:Replace light that does not come on. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right rear turn light (E1) and right front turn light (E3). See Front Frame Harness (W2) Wiring Diagram and See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check circuit L10 BRN for ground at pin 3 of right rear turn light (E1) harness connector. Check circuit L10 BRN for ground at pin 1 of right front turn light (E3) harness connector. Is ground present?
Result: YES:Circuit L10 BRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. <- Go to Section TOC
Section 9001 page 451
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect right rear turn light (E1) and right front turn light (E3). See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 42 (circuit L10 BRN) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L10 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002386.03- Rotating Beacon Voltage High 11
The rotating beacon high side driver circuit is short to power.
Rotating Beacon Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect rotating beacon (H21). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit L06 BRN for voltage at pin 1 of rotating beacon (H21) harness connector. Is voltage present?
Result: YES:Circuit L06 BRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect rotating beacon (H21). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin H4 (circuit L06 BRN) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L06 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002386.05- Rotating Beacon Current Low 11
The rotating beacon high side driver circuit is open.
Rotating Beacon Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect rotating beacon (H21). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 24 volts to pin 1 and ground to pin 2 on rotating beacon light (H21). Does rotating beacon come on?
Result: YES:Go to Open Circuit Check. NO:Replace rotating beacon light. ( 3 ) Open Circuit Check
Action: Turn battery disconnect switch OFF. Disconnect rotating beacon (H21). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L06 BRN for continuity between pin H4 on CCU connector (X21) and pin 1 of rotating beacon (H21) harness connector. Check circuit G30 BLK for continuity between pin 2 of rotating beacon (H21) harness connector and machine ground. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuits that do not indicate continuity are open. Repair circuits or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002386.06- Rotating Beacon Current High 11
The rotating beacon is high side driver short to ground.
Rotating Beacon Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect rotating beacon (H21). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 24 volts to pin 1 and ground to pin 2 on rotating beacon (H21). Does rotating beacon come on?
Result: YES:Go to Short Circuit Check. NO:Replace rotating beacon light. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect rotating beacon (H21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L06 BRN for ground at pin 1 of rotating beacon (H21) harness connector. Is ground present?
Result: YES:Circuit L06 BRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect rotating beacon (H21). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin H4 (circuit L06 BRN) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit L06 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002392.03- Backup Light and Alarm Voltage High 11
The backup light and alarm high side driver circuit is short to power.
Backup Light and Alarm Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect right backup light (E15), left backup light (E16), and backup alarm (H1). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Ignition ON. Check circuit L04 BRN for voltage at pin 1 of right and left backup lights (E15 and E16) harness connector. Check circuit L04 BRN for voltage at ring terminal on backup alarm (H1). Is voltage present?
Result: YES:Circuit L04 BRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect right backup light (E15), left backup light (E16), and backup alarm (H1). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit L04 BRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L04 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). <- Go to Section TOC
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<- Go to Section TOC
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Section 9001 page 458
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002392.05- Backup Light and Alarm Current Low 11
The backup light and alarm high side driver circuit is open.
Backup Light and Alarm Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right backup light (E15), left backup light (E16), and backup alarm (H1). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Apply voltage and ground to the following components: 24 volts to pin 1 and ground to pin 2 on malfunctioning light (E15 or E16). 24 volts and ground to terminals on backup alarm (H1). Do lights come on and alarm sound?
Result: YES:Go to Open Circuit Check. NO:Replace component that does not function properly. ( 3 ) Open Circuit Check
Action: Turn battery disconnect switch OFF. Disconnect right backup light (E15), left backup light (E16) and backup alarm (H1). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between: Pin 1 (circuit L04 BRN) on CCU connector (X22) and pin 1 of right and left backup lights (E15 and E16). Pin 2 (circuit G11 BLK) of right and left backup lights (E15 and E16) and machine ground. Pin 1 (circuit L04 BRN) on CCU connector (X22) and ring terminal on backup alarm (H1). Ring terminal (circuit G11 BLK) of backup alarm (H1) and machine ground Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuits that do not indicate continuity are open. Repair circuits or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Diagram . (Group 9015-10.)
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002392.06- Backup Light and Alarm Current High 11
The backup light and alarm high side driver circuit is short to ground.
Backup Light and Alarm Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right backup light (E15), left backup light (E16), and backup alarm (H1). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Apply voltage and ground to the following components: 24 volts to pin 1 and ground to pin 2 on malfunctioning light (E15 or E16). 24 volts and ground to terminals on backup alarm (H1). Do lights come on and alarm sound?
Result: YES:Go to Short Circuit Check. NO:Replace component that does not function properly. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right backup light (E15), left backup light (E16), and backup alarm (H1). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check circuit L04 BRN for ground at pin 1 of right and left backup lights (E15 and E16) harness connector. Check circuit L04 BRN for ground at ring terminal on backup alarm (H1). Is ground present?
Result: YES:Circuit L04 BRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Action: Turn battery disconnect switch OFF. Disconnect right backup light (E15), left backup light (E16), and backup alarm (H1). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit L04 BRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L04 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 462
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002584.03- Low Brake Pressure Switch Voltage High 11
The brake accumulator low pressure switch circuit is short to power.
Low Brake Pressure Switch Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect brake accumulator low pressure switch (B35). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check sensor. See Electrical Component Specifications . (Group 9015-20.) Is sensor to specification?
Result: YES:Go to Short Circuit Check. NO:Replace brake accumulator low pressure switch (B35). ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect brake accumulator low pressure switch (B35). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit N15 YEL for voltage at pin 2 of brake accumulator low pressure switch (B35) harness connector. Is voltage present?
Result: YES:Circuit N15 YEL is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect brake accumulator low pressure switch (B35). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 26 (circuit N15 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 463
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit N15 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 464
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002584.04- Low Brake Pressure Switch Voltage Low 11
The brake accumulator low pressure switch circuit is short to ground.
Low Brake Pressure Switch Volage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect brake accumulator low pressure switch (B35). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check sensor. See Electrical Component Specifications . (Group 9015-20.) Is sensor to specification?
Result: YES:Go to Short Circuit Check. NO:Replace brake accumulator low pressure switch (B35). ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect brake accumulator low pressure switch (B35). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check circuit N15 YEL for ground at pin 2 of brake accumulator low pressure switch (B35) harness connector. Is ground present?
Result: YES:Circuit N15 YEL is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect brake accumulator low pressure switch (B35). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 26 (circuit N15 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated? <- Go to Section TOC
Section 9001 page 465
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit N15 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002598.03- Articulation Reverse Light Voltage High 11
The articulation backup light high side driver circuit is short to power.
Articulation Reverse Light Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect left and right articulation backup lights (E17 and E18). See Rear Work Lights Harness (W14) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit L27 BRN for voltage at pin 2 of left and right articulation backup lights (E17 and E18) harness connectors. Is voltage present?
Result: YES:Circuit L27 BRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect left and right articulation backup lights (E17 and E18). See Rear Work Lights Harness (W14) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin L4 (circuit L27 BRN) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L27 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002598.05- Articulation Reverse Light Current Low 11
The articulation reverse light high side driver circuit is open.
Articulation Reverse Light Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left and right articulation backup lights (E17 and E18). See Rear Work Lights Harness (W14) Component Location . (Group 9015-10.) Apply 24 volts to pin 2 and ground to pin 1 on lights (E17 and E18). Do lights come on?
Result: YES:Go to Open Circuit Check. NO:Replace light that does not come on. ( 3 ) Open Circuit Check
Action: Turn battery disconnect switch OFF. Disconnect left and right articulation backup lights (E17 and E18). See Rear Work Lights Harness (W14) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin L4 (circuit L27 BRN) of CCU connector (X21) and pin 2 on left and right articulation backup lights (E17 and E18) harness connectors. Check for continuity between pin 1 (circuit G48 BLK) of left and right articulation backup lights (E17 and E18) and machine ground. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002598.06- Articulation Reverse Light Current High 11
The articulation backup light high side driver circuit is short to ground.
Articulation Reverse Light Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left and right articulation backup lights (E17 and E18). See Rear Work Lights Harness (W14) Component Location . (Group 9015-10.) Apply 24 volts to pin 2 and ground to pin 1 on lights (E17 and E18). Do lights come on?
Result: YES:Go to Short Circuit Check. NO:Replace light that does not come on. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left and right articulation backup light (E17 and E18). See Rear Work Lights Harness (W14) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L27 BRN for ground at pin 2 of left and right articulation backup lights (E14) harness connectors. Is ground present?
Result: YES:Circuit L27 BRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect left and right articulation backup lights (E17 and E18). See Rear Work Lights Harness (W14) Component Location . (Group 9015-10.) <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin L4 (circuit L27 BRN) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L27 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002641.03- Horn Voltage High 11
The electric horn high side driver circuit is short to power.
Horn Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect electric horn (B3). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check for voltage at circuit A05 ORG terminal ring at electric horn (B3). Is voltage present?
Result: YES:Circuit A05 ORG is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect electric horn (B3). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 3 (circuit A05 ORG) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit A05 ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002641.05- Horn Current Low 11
The electric horn high side driver circuit is open.
Horn Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect electric horn (B3). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Apply 24 volts and ground to electric horn (B3). Does electric horn function?
Result: YES:Go to Open Circuit Check. NO:Replace electric horn. ( 3 ) Open Circuit Check
Action: Turn battery disconnect switch OFF. Disconnect electric horn (B3). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 3 (circuit A05 ORG) on CCU connector (X23) and circuit A05 ORG terminal ring at electric horn (B3). Check for continuity between terminal ring (G58 BLK) at electric horn and machine ground. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002641.06- Horn Current High 11
The electric horn high side driver circuit is short to ground.
Horn Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect electric horn (B3). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Apply 24 volts and ground to electric horn (B3). Does electric horn function?
Result: YES:Go to Short Circuit Check. NO:Replace electric horn. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect electric horn (B3). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for ground at circuit A05 ORG terminal ring at electric horn (B3). Is ground present?
Result: YES:Circuit A05 ORG is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect electric horn (B3). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 3 (circuit A05 ORG) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit A05 ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002642.03- Mirror Heater Voltage High 11
The mirror defrost high side driver circuit is short to power.
Mirror Heater Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect left mirror defrost (R12) at cab harness-to-left mirror harness 6-pin connector (X36). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect right mirror defrost (R13) at cab harness-to-right mirror harness 6-pin connector (X37). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check for voltage at pin 2 (circuit P53 RED) of connectors (X36 and X37). Is voltage present?
Result: YES:Circuit P53 RED is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect left mirror defrost (R12) at cab harness-to-left mirror harness 6-pin connector (X36). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect right mirror defrost (R13) at cab harness-to-right mirror harness 6-pin connector (X37). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin M3 (circuit P53 RED) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit P53 RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002642.05- Mirror Heater Current Low 11
The mirror defrost high side driver circuit is open.
Mirror Heater Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left mirror defrost (R12) at cab harness-to-left mirror harness 6-pin connector (X36). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect right mirror defrost (R13) at cab harness-to-right mirror harness 6-pin connector (X37). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pins 1 and 2 on connectors (X36 and X37). Is continuity indicated?
Result: YES:Go to Open Circuit Check. NO:Replace mirrors that do not indicate continuity. ( 3 ) Open Circuit Check
Action: Turn battery disconnect switch OFF. Disconnect left mirror defrost (R12) at cab harness-to-left mirror harness 6-pin connector (X36). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect right mirror defrost (R13) at cab harness-to-right mirror harness 6-pin connector (X37). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin M3 (circuit P53 RED) on CCU connector (X21) and pin 2 on connector (X36). Check for continuity between pin 1 (circuit G34 BLK) on connector (X36) and machine ground. Check for continuity between pin M3 (circuit P53 RED) on CCU connector (X21) and pin 2 on connector (X37). Check for continuity between pin 1 (circuit G34 BLK) on connector (X37) and machine ground. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
(Group 9015-10.)
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002642.06- Mirror Heater Current High 11
The mirror defrost high side driver circuit is short to ground.
Mirror Heater Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left mirror defrost (R12) at cab harness-to-left mirror harness 6-pin connector (X36). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect right mirror defrost (R13) at cab harness-to-right mirror harness 6-pin connector (X37). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pins 1 and 2 on connectors (X36 and X37). Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Replace mirrors that do not indicate continuity. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left mirror defrost (R12) at cab harness-to-left mirror harness 6-pin connector (X36). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect right mirror defrost (R13) at cab harness-to-right mirror harness 6-pin connector (X37). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for ground at pin 2 (circuit P53 RED) on connectors (X36 and X37). Is ground present?
Result: YES:Circuit P53 RED is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Action: Turn battery disconnect switch OFF. Disconnect left mirror defrost (R12) at cab harness-to-left mirror harness 6-pin connector (X36). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect right mirror defrost (R13) at cab harness-to-right mirror harness 6-pin connector (X37). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin M3 (circuit P53 RED) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit P53 RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 002827.07- Neutral Mismatch Mechanical Fault 11
The neutral position CAN signal is missing from transmission control unit (TCU) at startup.
Neutral Mismatch Mechanical Fault Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Cycle ignition OFF and ON. Does DTC “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code (DTC) Check. ( 2 ) Diagnostic Trouble Code (DTC) Check
Action: Check for active transmission control unit (TCU) DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are active TCU trouble codes present?
Result: YES:Resolve active TCU DTCs. NO:Go to CAN Circuit Check. ( 3 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good? <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Program chassis control unit (CCU). NO:Repair CAN circuit. 002833.31- Park Brake Not Holding 11
The output shaft speed is greater than zero with park brake applied.
Park Brake Not Holding Diagnostic Procedure Alarm Level: Stop Icon (red) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code (DTC) Check. ( 2 ) Diagnostic Trouble Code (DTC) Check
Action: Check for active DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are active trouble codes present?
Result: YES:Resolve DTCs. NO:Go to Park Brake Check. ( 3 ) Park Brake Check
Action: Check park brake. See Park Brake Test . (Group 9020-25.) Does park brake check good?
Result: YES:Program chassis control unit (CCU). NO: See Park Brake Will Not Hold . (Group 9020-15.)
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
002876.04- Turn Signal Switch Voltage Low 11
The turn signal circuit is short to ground.
Turn Signal Switch Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code (DTC) Check. ( 2 ) Diagnostic Trouble Code (DTC) Check
Action: Ignition ON. Verify turn signal switch is in the neutral (center) position. Clear codes from chassis control unit (CCU). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Check for active DTCs. Is DTC 002876.04 still active?
Result: YES:Go to Short to Ground Check. NO: Go to Turn Signal Check . ( 3 ) Short to Ground Check
Action: Disconnect steering column switch (S2). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L23 BRN for ground at pin 9 on steering column switch (S2). Check circuit L20 BRN for ground at pin 10 on steering column switch (S2). Is ground present at either pin?
Result: YES:Circuit with ground present is short to ground. Replace or repair harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Turn Signal Check. ( 4 ) Turn Signal Check
Action: Ignition ON. Verify turn signal switch is in the neutral (center) position and code 002876.04 is not active. Activate the right and left turn signals (move lever to the up and down positions. Check for active DTCs. <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is DTC 002876.04 active?
Result: YES:Circuit P57 RED is short to ground. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 483
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
003509.03- Sensor Supply 1 Voltage High 11
The 5-volt reference number 1 circuit is short to power.
Sensor Supply 1 Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body position sensor (B6). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Ignition ON. Check circuit P22 RED for voltage at pin 2 on dump body lever position sensor (B25) connector. Is 5 volts or more present?
Result: YES:Circuit P22 RED is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect dump body lever position sensor (B25). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin E2 (circuit P22 RED) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit P22 RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 484
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
003509.04- Sensor Supply 1 Voltage Low 11
The 5-volt reference number 1 circuit is open or short to ground.
Sensor Supply 1 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body position sensor (B6). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check circuit P22 RED for ground at pin 2 on dump body position sensor (B6) connector. Is ground present?
Result: YES:Circuit P22 RED is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect dump body position sensor (B6). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 2 (circuit P22 RED) of dump body position sensor (B6) connector and pin E2 of CCU connector (X21). Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuit P22 RED is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect dump body lever position sensor (B25). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin E2 (circuit P22 RED) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit P22 RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
003510.03- Sensor Supply 2 Voltage High 11
The 5-volt reference number 2 circuit is short to power.
Sensor Supply 2 Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect left fan speed sensor (B7). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit P50 RED for voltage at pin A on left fan speed sensor (B7) connector. Is 5 volts or more present?
Result: YES:Circuit P50 RED is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect left fan speed sensor (B7). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin E1 (circuit P50 RED) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit P50 RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
003510.04- Sensor Supply 2 Voltage Low 11
The 5-volt reference number 2 circuit is open or short to ground.
Sensor Supply 2 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect left fan speed sensor (B7). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit P50 RED for ground at pin A of sensor (B7) connector. Is ground present?
Result: YES:Circuit P50 RED is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 3 ) Open Circuit Check
Action: Disconnect left fan speed sensor (B7). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin A (circuit P50 RED) of left fan speed sensor (B7) connector and pin E1 of CCU connector (X21). Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuit P50 RED is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect left fan speed sensor (B7). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin E1 (circuit P50 RED) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit P50 RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
003511.03- Sensor Supply 3 Voltage High 11
The 5-volt reference number 3 circuit is short to power.
Sensor Supply 3 Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect hydraulic pressure sensor (B12). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit P51 RED for voltage at pin A on hydraulic pressure sensor (B12) connector. Is 5 volts or more present?
Result: YES:Circuit P51 RED is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect hydraulic pressure sensor (B12). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin E3 (circuit P51 RED) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit P51 RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
003511.04- Sensor Supply 3 Voltage Low 11
The 5-volt reference number 3 circuit is open or short to ground.
Sensor Supply 3 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect hydraulic pressure sensor (B12). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check circuit P51 RED for ground at pin A on hydraulic pressure sensor (B12) connector. Is ground present?
Result: YES:Circuit P51 RED is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 3 ) Open Circuit Check
Action: Disconnect hydraulic pressure sensor (B12). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin A (circuit P51 RED) of hydraulic pressure sensor (B51) connector and pin E3 of CCU connector (X21). Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuit P51 RED is open. Repair circuit or replace harness. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect hydraulic pressure sensor (B12). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin E3 (circuit P51 RED) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit P51 RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 492
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
003981.03- HVAC Mode Control Actuator Voltage High 11
HVAC mode control actuator control signal short to power.
HVAC Mode Control Actuator Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, See Air Conditioner and Heater Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect air conditioner actuator control unit connector (X85). See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check for power on pin 3 (circuit 15 WHT) at air conditioner actuator control unit connector (X85). Is power measured?
Result: YES:Circuit 15 WHT is short to power. Repair or replace harness. See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect air conditioner actuator control unit connector (X85). See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 41 (circuit A22 ORG) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit A22 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Go to Code Check. ( 4 ) Code Check
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. . (Group 9015-20.) Is DTC 3981.03 still active?
Result: YES:Replace defrost/middle vent actuator (M7).Program controller. NO:Checks complete.
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
003981.06- HVAC Mode Control Actuator Current High 11
HVAC Mode Control Actuator control signal short to ground.
HVAC Mode Control Actuator Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, See Air Conditioner and Heater Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect air conditioner actuator control unit connector (X85). See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for ground on pin 3 (circuit 15 WHT) at air conditioner actuator control unit connector (X85). Is ground present?
Result: YES:Circuit 15 WHT is short to ground. Repair or replace harness. See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect air conditioner actuator control unit connector (X85). See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 41 (circuit A22 ORG) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit A22 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Go to Code Check. ( 4 ) Code Check
<- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. . (Group 9015-20.) Is DTC 3981.06 still active?
Result: YES:Replace defrost/middle vent actuator (M7).Program controller. NO:Checks complete.
<- Go to Section TOC
Section 9001 page 496
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
003984.03- HVAC Recirculation Door Control Actuator Voltage High 11
HVAC recirculation door control actuator control signal short to power.
HVAC Recirculation Door Control Actuator Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, See Air Conditioner and Heater Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect air conditioner actuator control unit connector (X85). See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check for power on pin 4 (circuit 16 WHT) at air conditioner actuator control unit connector (X85). Is power measured?
Result: YES:Circuit 16 WHT is short to power. Repair or replace harness. See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect recirculation vent actuator (M6). See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 53 (circuit A24 ORG) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit A24 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Go to Code Check. ( 4 ) Code Check
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. . (Group 9015-20.) Is DTC 3984.03 still active?
Result: YES:Replace recirculation vent actuator (M6).Program controller. NO:Checks complete.
<- Go to Section TOC
Section 9001 page 498
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
003984.06- HVAC Recirculation Door Control Actuator Current High 11
HVAC recirculation door control actuator control signal short to ground.
HVAC Recirculation Door Control Actuator Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, See Air Conditioner and Heater Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect air conditioner actuator control unit connector (X85). See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for ground on pin 4 (circuit 16 WHT) at air conditioner actuator control unit connector (X85). Is ground present?
Result: YES:Circuit 16 WHT is short to ground. Repair or replace harness. See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect recirculation vent actuator (M6). See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 53 (circuit A24 ORG) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit A24 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Go to Code Check. ( 4 ) Code Check
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. . (Group 9015-20.) Is DTC 3984.06 still active?
Result: YES:Replace recirculation vent actuator (M6).Program controller. NO:Checks complete.
<- Go to Section TOC
Section 9001 page 500
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
003986.03- HVAC Temperature Control Actuator Voltage High 11
Temperature actuator control signal short to power.
HVAC Temperature Control Actuator Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, See Air Conditioner and Heater Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect air conditioner actuator control unit connector (X85). See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check for power on pin 1 (circuit 13 WHT) at air conditioner actuator control unit connector (X85). Is power measured?
Result: YES:Circuit 13 WHT is short to power. Repair or replace harness. See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect heater control valve actuator (M2). See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 29 (circuit A25 ORG) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit A25 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Go to Code Check. ( 4 ) Code Check
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. . (Group 9015-20.) Is DTC 3986.03 still active?
Result: YES:Replace heater control valve actuator (M2).Program controller. NO:Checks complete.
<- Go to Section TOC
Section 9001 page 502
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
003986.06- HVAC Temperature Control Actuator Current High 11
Temperature actuator control signal short to ground.
HVAC Temperature Control Actuator Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, See Air Conditioner and Heater Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect air conditioner actuator control unit connector (X85). See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for ground on pin 1 (circuit 13 WHT) at air conditioner actuator control unit connector (X85). Is ground present?
Result: YES:Circuit 13 WHT is short to ground. Repair or replace harness. See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect heater control valve actuator (M2). See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 29 (circuit A25 ORG) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit A25 ORG is short to circuit with continuity indicated. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Component Location. . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Go to Code Check. ( 4 ) Code Check
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. . (Group 9015-20.) <- Go to Section TOC
Section 9001 page 503
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is DTC 3986.06 still active?
Result: YES:Replace heater control valve actuator (M2).Program controller. NO:Checks complete.
<- Go to Section TOC
Section 9001 page 504
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
005557.03- Fan 2 Reverse Sol Voltage High 11
The right side reversing fan solenoid high side driver circuit is short to power.
Fan 2 Reverse Sol Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect right side reversing fan solenoid (Y51). See Engine Harness (W17) Component Location . (Group 9015-10.) Ignition ON. Check circuit H38 GRN for voltage at pin 1 of right side reversing fan solenoid (Y51) harness connector. Is voltage present?
Result: YES:Circuit H38 GRN is short to power. Repair circuit or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Ignition OFF. Disconnect right side reversing fan solenoid (Y51). See Engine Harness (W17) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin H1 of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H38 GRN is short to circuit with continuity indicated. Repair or replace circuits. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 505
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
005557.05- Fan 2 Reverse Sol Current Low 11
Right side fan reversing solenoid high side driver circuit is open.
Fan 2 Reverse Sol Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right side reversing fan solenoid (Y51). See Engine Harness (W17) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on right side reversing fan solenoid (Y51). See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Right side reversing fan solenoid (Y51) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect right side reversing fan solenoid (Y51). See Engine Harness (W17) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H38 GRN for continuity between pin H1 of CCU connector (X21) harness connector and pin 1 of right side reversing fan solenoid (Y51) harness connector. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 506
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
005557.06- Fan 2 Reverse Sol Current High 11
Right side reversing fan solenoid high side driver circuit is short to ground.
Fan 2 Reverse Sol Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right side reversing fan solenoid (Y51). See Engine Harness (W17) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on right side reversing fan solenoid (Y51). See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Right side reversing fan solenoid (Y51) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right side reversing fan solenoid (Y51). See Engine Harness (W17) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H38 GRN for ground at pin 1 on right side reversing fan solenoid (Y51) harness connector. Is ground present?
Result: YES:Circuit H38 GRN is short to ground. Repair circuit or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Engine Harness (W17) Component Location . (Group 9015-10.) Disconnect right side reversing fan solenoid (Y51). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin H1 (circuit H38 GRN) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H38 GRN is short to circuit with continuity indicated. Repair or replace circuit. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 005562.00- Fan 2 Speed Very High 11
The right side fan speed is much faster than command.
Fan 2 Speed Very High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other hydraulic fan diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to Component Check. ( 3 ) Component Check
Action: Ignition OFF. Disconnect right side fan speed sensor (B8). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance across pins A and B on right side fan speed sensor (B8). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Program chassis control unit (CCU). NO:Right side fan speed sensor malfunction. Replace sensor.
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
005562.01- Fan 2 Speed Very Low 11
The right side fan speed is much slower than command.
Fan 2 Speed Very Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other hydraulic fan diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to Component Check. ( 3 ) Component Check
Action: Ignition OFF. Disconnect right side fan speed sensor (B8). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance across pins A and B on right side fan speed sensor (B8). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Hydraulic Fan Circuit Flow Check. NO:Right side fan speed sensor malfunction. Replace sensor. ( 4 ) Hydraulic Fan Circuit Flow Check
Action: Perform hydraulic fan circuit flow test. See Hydraulic Fan Circuit Flow Test . (Group 9025-25.) Is fan circuit flow within specification?
Result: YES:Program chassis control unit (CCU). NO:Check the main hydraulic pump margin and maximum pressure. See Main Hydraulic Pump Margin and maximum Pressure Test and Adjustment . (Group 9025-25.) <- Go to Section TOC
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<- Go to Section TOC
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Section 9001 page 510
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
005562.08- Fan 2 Speed Bad Freq Data 11
The right side fan speed is zero with fan moving.
Fan 2 Speed Bad Freq Data Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is DTC 001639.08 present?
Result: YES:Go to Open Circuit Check . NO:Go to Component Check. ( 3 ) Component Check
Action: Ignition OFF. Disconnect right side fan speed sensor (B8). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance across pins A and B on right side fan speed sensor (B8). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Right side fan speed sensor malfunction. Replace sensor. ( 4 ) Open Circuit Check
Action: Ignition OFF. Disconnect right side fan speed sensor (B8). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21 and X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin A (circuit P50 RED) of sensor (B8) connector and pin E1 of CCU connector (X21). Check for continuity between pin B (circuit R51 BLK) of sensor (B8) connector and pin F1 of CCU connector (X21). Check for continuity between pin C (circuit M23 PUR) of sensor (B8) connector and pin 50 of CCU connector (X22). <- Go to Section TOC
Section 9001 page 511
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 512
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
005563.03- Fan 2 Solenoid Voltage High 11
The right side fan speed solenoid high side driver circuit is short to power.
Fan 2 Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect right side fan speed solenoid (Y71). See Articulation Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit H11 GRN for voltage at pin A of right side fan speed solenoid (Y71) harness connector. Is voltage present?
Result: YES:Circuit H11 GRN is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Ignition OFF. Disconnect right side fan speed solenoid (Y71). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin G1 of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H11 GRN is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
005563.05- Fan 2 Solenoid Current Low 11
The right side fan speed solenoid high side driver circuit is open.
Fan 2 Solenoid Current Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Open Circuit Check. ( 2 ) Open Circuit Check
Action: Ignition OFF. Disconnect right side fan speed solenoid (Y71). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H11 GRN for continuity between pin D4 of CCU connector (X21) harness connector and pin A of right side fan speed solenoid (Y71) harness connector. Is continuity indicated?
Result: YES:Go to Code Check. NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 3 ) Code Check
Action: Ignition ON. Is code 005563.05 still present?
Result: YES:Right side fan speed solenoid (Y71) malfunction. Replace solenoid. See Articulation Harness (W9) Component Location . (Group 9015-10.) Program chassis control unit (CCU). NO:Check complete.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
005563.06- Fan 2 Solenoid Current High 11
The right side fan speed solenoid high side driver circuit is short to ground.
Fan 2 Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right side fan speed solenoid (Y71). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Right side fan speed solenoid (Y71) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right side fan speed solenoid (Y71). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H11 GRN for ground at pin A on right side fan speed solenoid (Y71) harness connector. Is ground present?
Result: YES:Circuit H11 GRN is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect right side fan speed solenoid (Y71). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin G1 (circuit H11 GRN) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit H11 GRN is short to circuit with continuity indicated. Repair or replace circuit. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
005563.16- Fan 2 Current Moderately High 11
The right side fan speed solenoid low side driver circuit is short to ground.
Fan 2 Current Moderately High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right side fan speed solenoid (Y71). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Right side fan speed solenoid (Y71) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right side fan speed solenoid (Y71). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R34 BLK for ground at pin B on right side fan speed solenoid (Y71) harness connector. Is ground present?
Result: YES:Circuit R34 BLK is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect right side fan speed solenoid (Y71). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin K2 (circuit R34 BLK) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit R34 BLK is short to circuit that indicated continuity. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
005563.17- Fan 2 Voltage Slightly Low 11
The right side fan speed solenoid low side driver circuit is open.
Fan 2 Voltage Slightly Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right side fan speed solenoid (Y71). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Right side fan speed solenoid (Y71) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect right side fan speed solenoid (Y71). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R34 BLK for continuity between pin K2 of CCU connector (X21) harness connector and pin B of right side fan speed solenoid (Y71) harness connector. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
005563.18- Fan 2 Voltage Moderately Low 11
The right side fan speed solenoid low side driver circuit is short to power.
Fan 2 Voltage Moderately Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right side fan speed solenoid (Y71). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Rght side fan speed solenoid (Y71) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right side fan speed solenoid (Y71). See Articulation Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit R34 BLK for voltage at pin B of right side fan speed solenoid (Y71) harness connector. Is approximately 5 volts present?
Result: YES:Circuit R34 BLK is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect right side fan speed solenoid (Y71). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin K2 of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit R34 BLK is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
005572.03- 12V Power Converter Voltage High 11
The 12-volt power converter circuit is open or short to power.
12V Power Converter Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Fuse Check. ( 2 ) Fuse Check
Action: Ignition OFF. Disconnect fuse (F33). See Fuse and Relay Specifications . (Group 9015-10.) Check fuse (F33) for continuity. Is continuity indicated?
Result: YES:Go to Open Circuit Check. NO:Replace fuse without continuity indicated. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect 24V to 12V DC Converter (U1) connector (X55). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Verify fuse (F33) is present and has continuity. Check circuit P73 RED for continuity between pin 5 on converter (U1) connector (X55) and pin 8 on chassis control unit (CCU) connector (X23). Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 4 ) Short Circuit Check
Action: Ignition OFF. Disconnect 24V to 12V DC Converter (U1) connector (X55). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Verify fuse (F33) is present and has continuity. Ignition ON. Check circuit P73 RED for voltage at pin 8 on chassis control unit (CCU) connector (X23). Is 15.8 volts or more present?
Result: YES:Circuit P73 RED is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 5 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect 24V to 12V DC converter (U1) connector (X55). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Verify fuse (F33) is present and has continuity. Check for continuity between pin 8 (circuit P73 RED) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit P73 RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
005572.04- 12V Power Converter Voltage Low 11
The 12-volt power converter circuit is short to ground.
12V Power Converter Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Fuse Check. ( 2 ) Fuse Check
Action: Ignition OFF. Disconnect fuse (F33). See Fuse and Relay Specifications . (Group 9015-10.) Check fuse (F33) for continuity. Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Replace fuse without continuity indicated. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect 24V to 12V DC converter (U1) connector (X55). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Verify fuse (F33) is present and has continuity. Check circuit P73 RED for ground at pin 8 on chassis control unit (CCU) connector (X23). Is 15.8 volts or more present?
Result: YES:Circuit P73 RED is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect 24V to 12V DC converter (U1) connector (X55). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Verify fuse (F33) is present and has continuity. Check for continuity between pin 8 (circuit P73 RED) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit P73 RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
008112.31- OBW Strain Gauge Error 11
Strain gauge malfunction occurred.
OBW Strain Gauge Error Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Controller Check
Action: →NOTE: This check is used to check for communication between on board weighing (OBW) controller, chassis control unit (CCU), and the CAN monitor unit (CMU). Is a weight displayed on the CMU?
Result: YES:Go to Ignition ON/OFF Check. NO: Go to CAN Circuit Check . ( 2 ) Ignition ON/OFF Check
Action: Ignition ON. Ignition OFF. Wait for 1 minute. Ignition ON. Check for active codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Is code 008112.31 present?
Result: YES:Go to Voltage Check. NO:Checks complete. ( 3 ) Voltage Check
Action: Ignition OFF. Disconnect OBW controller (A18). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Ignition ON. Check for voltage between pin 4 and ground (pin 3). Is system voltage (approximately 24 volts) present?
Result: YES:Go to CAN Circuit Check. NO:Check wiring harness. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Rear <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Frame Harness (W12) Wiring Diagram . (Group 9015-10.) ( 4 ) CAN Circuit Check
Action: Test controller area network (CAN) circuit. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Go to Resistance Check. NO:Repair CAN circuit. ( 5 ) Resistance Check
Action: Ignition OFF. Disconnect OBW controller (A18) and left and right strain gauge connectors (X27 and X28). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check resistance between pin 11 and pins 1 and 2 of OBW controller connector (A18). Check resistance between pin 12 and pins 1 and 2 of OBW controller connector (A18). Are approximately 90 ohms present?
Result: YES:Continue check. NO:Repair or replace wiring harness. See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.)
Action: Check resistance between pin 1 and pin 2 of OBW controller (A18). Check resistance between pin 1 and pins 2 and 3 of left and right strain gauge connectors (X27 and X28). Are approximately 120 ohms present?
Result: YES:Continue check. NO:Repair or replace wiring harness. See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.)
Action: Check resistance between pin 2 and pin 3 of left and right strain gauge connectors (X27 and X28). Are approximately 240 ohms present?
Result: YES:If all resistance checks are good but the weight on the CMU still fluctuates, the strain gauge might be malfunctioning. Go to Left Strain Gauge Check. NO:Repair or replace wiring harness. See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) ( 6 ) Left Strain Gauge Check
Action: Ignition OFF. Connect right strain gauge connector (X28) and OBW controller connector (A18). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Connect JDG11414 OBW Strain Gauge to left strain gauge connector (X27) to simulate the strain gauge. Ignition ON. Does the weight still fluctuate on the CMU?
Result: YES:Go to Right Strain Gauge Check. NO:Left strain gauge malfunction. Replace left strain gauge. See Strain Gauge Remove and Install . (Group 0242.) ( 7 ) Right Strain Gauge Check
Action: Ignition OFF. Connect left strain gauge connector (X27) and OBW controller (A18). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Connect JDG11414 OBW Strain Gauge to right strain gauge connector (X28) to simulate the strain gauge. Ignition ON. Does the weight still fluctuate on the CMU?
Result: YES:Replace OBW controller. See Electronic Controllers Remove and Install . (Group 9015-20.) NO:Right strain gauge malfunction. Replace right strain gauge. See Strain Gauge Remove and Install . (Group 0242.) 010000.09- Converter Output Voltage Low 11
The converter output voltage low.
Converter Output Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Diagnostic Trouble Code (DTC) Check
Action: Check for active DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are active trouble codes present?
Result: YES:Resolve DTCs. NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Verify fuse (F33) is present and has continuity. See Fuse and Relay Specifications . (Group 9015-10.) Ignition ON. Check circuit P73 RED for voltage at pin 8 on chassis control unit (CCU) connector (X23). Is 15.6 volts or less present? <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Program chassis control unit (CCU). NO:12V converter (U1) malfunction. Replace converter. 299621.02- Intermittent Configuration Error 11
There is a reporting error by the chassis control unit (CCU).
Intermittent Configuration Error Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other CAN communication diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Program chassis control unit (CCU).
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520749.05- HVAC Blower HI Speed Current Low 11
The HVAC blower high speed high side driver circuit is open.
HVAC Blower HI Speed Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect circuit 1 WHT and 4 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Check for continuity between circuit 1 WHT terminal on resistor R1 and circuit 4 WHT terminal on resistor R1. Is continuity indicated?
Result: YES:Go to Open Circuit Check. NO:Replace blower motor resistor/thermofuse. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect circuit 1 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit 1 WHT for continuity between pin 1 on harness connector (X46) and circuit 1 WHT terminal at blower motor resistor/thermofuse (R11). Is continuity indicated?
Result: YES:Continue to next check. NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Wiring Diagram . (Group 9015-10.)
Action: Ignition OFF. Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A26 ORG for continuity between pin 1 on harness connector (X46) and pin 4 on CCU connector (X23). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520749.06- HVAC Blower HI Speed Current High 11
The HVAC blower high speed high side driver circuit is short to ground.
HVAC Blower HI Speed Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect circuit 1 WHT and 4 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Check for continuity between circuit 1 WHT terminal on resistor R1 and circuit 4 WHT terminal on resistor R1. Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Replace blower motor resistor/thermofuse. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect circuit 1 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit 1 WHT for ground at pin 1 on harness connector (X46). Is ground present?
Result: YES:Circuit 1 WHT is short to ground. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Wiring Diagram . (Group 9015-10.) NO:Continue to next check.
Action: Ignition OFF. Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A26 ORG for ground at pin 4 on CCU connector (X23). Is ground present?
Result: YES:Circuit A26 ORG is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect circuit 1 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit 1 WHT) of connector (X46) and all other pins on cab harness-to-air conditioner harness connector (X46). Is continuity indicated?
Result: YES:Circuit 1 WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
Action: Turn battery disconnect OFF. Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 4 (circuit A26 ORG) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit that indicated continuity to another pin is short. Repair circuit or replace harness. See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520818.05- HVAC Blower Medium Speed Current Low 11
The HVAC blower medium speed high side driver circuit is open.
HVAC Blower Medium Speed Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect circuit 2 WHT and 4 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Check for continuity between circuit 2 WHT terminal on resistor R1 and circuit 4 WHT terminal on resistor R1. Is continuity indicated?
Result: YES:Go to Open Circuit Check. NO:Replace blower motor resistor/thermofuse. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect circuit 2 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit 2 WHT for continuity between pin 2 on harness connector (X46) and circuit 2 WHT terminal at blower motor resistor/thermofuse (R11). Is continuity indicated?
Result: YES:Continue to next check. NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Wiring Diagram . (Group 9015-10.)
Action: Ignition OFF. Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 534
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A02 ORG for continuity between pin 2 on harness connector (X46) and pin 4 on CCU connector (X23). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520818.06- HVAC Blower Medium Speed Current High 11
The HVAC blower medium speed high side driver circuit is short to ground.
HVAC Blower Medium Speed Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect circuit 2 WHT and 4 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Check for continuity between circuit 2 WHT terminal on resistor/thermofuse (R11) and circuit 4 WHT terminal on resistor/thermofuse (R11). Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Replace blower motor resistor/thermofuse. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect circuit 2 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit 2 WHT for ground at pin 2 on harness connector (X46). Is ground present?
Result: YES:Circuit 2 WHT is short to ground. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Wiring Diagram . (Group 9015-10.) NO:Continue to next check.
Action: Ignition OFF. Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A02 ORG for ground at pin L3 on CCU connector (X21). Is ground present?
Result: YES:Circuit A02 ORG is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect circuit 2 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 2 (circuit 2 WHT) of connector (X46) and all other pins on cab harness-to-air conditioner harness connector (X46). Is continuity indicated?
Result: YES:Circuit 2 WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
Action: Turn battery disconnect OFF. Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin L3 (circuit A02 ORG) of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit that indicated continuity to another pin is short. Repair circuit or replace harness. See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520820.05- HVAC Blower Low Speed Current Low 11
The HVAC blower low speed high side driver circuit is open.
HVAC Blower Low Speed Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics. (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect circuit 3 WHT and 4 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Check for continuity between circuit 3 WHT terminal on resistor/thermofuse (R11) and circuit 4 WHT terminal on resistor/thermofuse (R11). Is continuity indicated?
Result: YES:Go to Open Circuit Check. NO:Replace blower motor resistor/thermofuse. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect circuit 3 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit 3 WHT for continuity between pin 3 on harness connector (X46) and circuit 3 WHT terminal at blower motor resistor/thermofuse (R11). Is continuity indicated?
Result: YES:Continue to next check. NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Wiring Diagram . (Group 9015-10.)
Action: Ignition OFF. Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group <- Go to Section TOC
Section 9001 page 538
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A03 ORG for continuity between pin 3 on harness connector (X46) and pin L3 on CCU connector (X21). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 539
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520820.06- HVAC Blower Low Speed Current High 11
The HVAC blower low speed high side driver circuit is short to ground.
HVAC Blower Low Speed Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect circuit 3 WHT and 4 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Check for continuity between circuit 3 WHT terminal on resistor/thermofuse (R11) and circuit 4 WHT terminal on resistor/thermofuse (R11). Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Replace blower motor resistor/thermofuse. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect circuit 3 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit 3 WHT for ground at pin 3 on harness connector (X46). Is ground present?
Result: YES:Circuit 3 WHT is short to ground. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Wiring Diagram . (Group 9015-10.) NO:Continue to next check.
Action: Ignition OFF. Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A03 ORG for ground at pin M4 on CCU connector (X21). Is ground present?
Result: YES:Circuit A03 ORG is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect circuit 3 WHT at blower motor resistor/thermofuse (R11). See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 3 (circuit 3 WHT) of connector (X46) and all other pins on cab harness-to-air conditioner harness connector (X46). Is continuity indicated?
Result: YES:Circuit 3 WHT is short to circuit that indicated continuity. Repair circuit or replace harness. See Air Conditioner Unit Harness (W16) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
Action: Turn battery disconnect OFF. Disconnect cab harness-to-air conditioner harness connector (X46). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin M4 (circuit A03 ORG) of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit that indicated continuity to another pin is short. Repair circuit or replace harness. See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 541
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520833.03- Body Raise Solenoid Voltage High 11
The dump body up control solenoid high side driver circuit is short to power.
Body Raise Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on dump body up control solenoid (Y24). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Dump body up control solenoid (Y24) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit H23 GRN for voltage at pin 1 on dump body up control solenoid (Y24) connector. Is voltage present?
Result: YES:Circuit H23 GRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 542
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin B4 (circuit H23 GRN) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H23 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 543
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520833.05- Body Raise Solenoid Current Low 11
The dump body up control solenoid high side driver circuit is open.
Body Raise Solenoid Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on dump body up control solenoid (Y24). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Dump body up control solenoid (Y24) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H23 GRN for continuity between pin 1 on dump body up control solenoid (Y24) connector and pin B4 on CCU connector X21. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 544
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520833.06- Body Raise Solenoid Current High 11
The dump body up control solenoid high side driver circuit is short to ground.
Body Raise Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on dump body up control solenoid (Y24). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Dump body up control solenoid (Y24) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check circuit H23 GRN for ground at pin 1 on dump body up control solenoid (Y24) connector. Is ground present?
Result: YES:Circuit H23 GRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin B4 (circuit H23 GRN) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
Section 9001 page 545
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit H23 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 546
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520833.16- Body Raise Solenoid Moderately High 11
The dump body up control solenoid low side driver circuit is short to ground.
Body Raise Solenoid Moderately High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on dump body up control solenoid (Y24). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Dump body up control solenoid (Y24) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check circuit R50 BLK for ground at pin 2 on dump body up control solenoid (Y24) connector. Is ground present?
Result: YES:Circuit R50 BLK is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin H2 (circuit R50 BLK) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
Section 9001 page 547
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit R50 BLK is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 548
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520833.17- Body Raise Solenoid Slightly Low 11
The dump body up control solenoid low side driver is open.
Body Raise Solenoid Slightly Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on dump body up control solenoid (Y24). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Dump body up control solenoid (Y24) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R50 BLK for continuity between pin 2 on dump body up control solenoid (Y24) connector and pin H2 on CCU connector X21. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 549
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520833.18- Body Raise Solenoid Moderately Low 11
The dump body up control solenoid low side driver circuit is short to power.
Body Raise Solenoid Moderately Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on dump body up control solenoid (Y24). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Dump body up control solenoid (Y24) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit R50 BLK for voltage at pin 1 on dump body up solenoid (Y24) connector. Is voltage present?
Result: YES:Circuit R50 BLK is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect dump body up control solenoid (Y24). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 550
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin H2 (circuit R50 BLK) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit R50 BLK is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 520835.01- Mid Axle Oil Filter Restricted 11
The mid axle oil filter is restricted.
Mid Axle Oil Filter Restricted Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the mid axle filter restriction switch (B68). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check for continuity between pins A and B on restriction switch (B68). Is continuity indicated?
Result: YES:Go to Hydraulic Oil Filter Check. NO:Mid axle filter restriction switch (B68) malfunction. Replace switch. ( 3 ) Hydraulic Oil Filter Check
Action: Remove mid axle oil filter. See Hydraulic System Component Location . (Group 9025-15.) Is filter clogged with excessive debris?
Result: YES:Replace filter. See Replace Axle Oil Filters . (Operator′s Manual.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 551
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520835.03- Mid Axle Oil Filter Voltage High 11
The mid axle oil filter restriction switch is short to power.
Mid Axle Oil Filter Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Disconnect the mid axle filter restriction switch (B68). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check circuit N07 YEL for voltage at pin B on restriction switch (B68) connector. Is voltage present?
Result: YES:Go to Harness Check. NO:Circuit N07 YEL is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect mid axle filter restriction switch (B68). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect CCU connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 34 (circuit N07 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit N07 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 520835.16- Mid Axle Oil Filter Stuck Open 11
The mid axle oil filter restriction switch is stuck open.
Mid Axle Oil Filter Stuck Open Diagnostic Procedure Alarm Level: Caution Icon (yellow) <- Go to Section TOC
Section 9001 page 552
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the mid axle filter restriction switch (B68). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check for continuity between pins A and B on restriction switch (B68). Is continuity indicated?
Result: YES:Problem intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Mid axle filter restriction switch (B68) malfunction. Replace switch. 520838.01- Rear Axle Oil Filter Restricted 11
The rear axle oil filter is restricted.
Rear Axle Oil Filter Restricted Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the rear axle filter restriction switch (B69). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check for continuity between pins A and B on restriction switch (B69). Is continuity indicated?
Result: YES:Go to Hydraulic Oil Filter Check. NO:Rear axle filter restriction switch (B69) malfunction. Replace switch. <- Go to Section TOC
Section 9001 page 553
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
( 3 ) Hydraulic Oil Filter Check
Action: Remove rear axle oil filter. See Hydraulic System Component Location . (Group 9025-15.) Is filter clogged with excessive debris?
Result: YES:Replace filter. See Replace Axle Oil Filters . (Operator′s Manual.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 554
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520838.03- Rear Axle Oil Filter Voltage High 11
The rear axle oil filter restriction switch is short to power.
Rear Axle Oil Filter Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Disconnect the rear axle filter restriction switch (B69). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check circuit N08 YEL for voltage at pin B on restriction switch (B69) connector. Is voltage present?
Result: YES:Go to Harness Check. NO:Circuit N08 YEL is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect rear axle filter restriction switch (B69). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect CCU connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 10 (circuit N08 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit N08 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 520838.16- Rear Axle Oil Filter Stuck Open 11
The rear axle oil filter restriction switch is stuck open.
Rear Axle Oil Filter Stuck Open Diagnostic Procedure Alarm Level: Caution Icon (yellow) <- Go to Section TOC
Section 9001 page 555
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the rear axle filter restriction switch (B69). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check for continuity between pins A and B on restriction switch (B69). Is continuity indicated?
Result: YES:Problem intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Rear axle filter restriction switch (B69) malfunction. Replace switch.
<- Go to Section TOC
Section 9001 page 556
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520841.00- Front Axle CDL Pressure Very High 11
The front cross axle differential lock (CDL) pressure is too high.
Front Axle CDL Pressure Very High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to next check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other front CDL diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to next check. ( 3 ) Component Check
Action: Ignition OFF. Disconnect front axle differential lock pressure sensor (B58). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance across pins A and B on front axle differential lock pressure sensor (B58). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to next Check. NO:Replace pressure sensor. ( 4 ) CDL Pressure Check
Action: Check front axle CDL pressure and adjust if necessary. See Cross-Axle Differential Lock (CDL) Pressure Test and Adjustment . (Group 9020-25.) Clear diagnostic trouble codes (DTCs) and test CDL operation. Is DTC 520841.00 still present?
<- Go to Section TOC
Section 9001 page 557
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Diagnose axle high pressure. See TEAMMATE™ V 1500 Series Axle 370E, 410E, 460E Series Outboard Planetary Axles . (CTM115319.) NO:Checks complete.
<- Go to Section TOC
Section 9001 page 558
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520841.01- Front Axle CDL Pressure Very Low 11
The front cross axle differential lock (CDL) pressure is too low.
Front Axle CDL Pressure Very Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to next check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other front CDL diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to next check. ( 3 ) Component Check
Action: Ignition OFF. Disconnect front axle differential lock pressure sensor (B58). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance across pins A and B on front axle differential lock pressure sensor (B58). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to next check. NO:Replace pressure sensor. ( 4 ) CDL Pressure Check
Action: Check front axle CDL pressure and adjust if necessary. See Cross-Axle Differential Lock (CDL) Pressure Test and Adjustment . (Group 9020-25.) Clear diagnostic trouble codes (DTCs) and test CDL operation. Is DTC 520841.01 still present?
<- Go to Section TOC
Section 9001 page 559
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Diagnose axle low pressure. See TEAMMATE™ V 1500 Series Axle 370E, 410E, 460E Series Outboard Planetary Axles . (CTM115319.) NO:Checks complete.
<- Go to Section TOC
Section 9001 page 560
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520842.00- Mid Axle CDL Pressure Very High 11
The middle cross axle differential lock (CDL) pressure is too high.
Mid Axle CDL Pressure Very High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to next check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other front CDL diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to next check. ( 3 ) Component Check
Action: Ignition OFF. Disconnect the middle axle differential lock pressure sensor (B59). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance across pins A and B on the middle axle differential lock pressure sensor (B59). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to next check. NO:Replace pressure sensor. ( 4 ) CDL Pressure Check
Action: Check middle axle CDL pressure and adjust if necessary. See Cross-Axle Differential Lock (CDL) Pressure Test and Adjustment . (Group 9020-25.) Clear diagnostic trouble codes (DTCs) and test CDL operation. Is DTC 520842.00 still present?
<- Go to Section TOC
Section 9001 page 561
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Diagnose axle high pressure. See TEAMMATE™ V 1500 Series Axle 370E, 410E, 460E Series Outboard Planetary Axles . (CTM115319.) NO:Checks complete.
<- Go to Section TOC
Section 9001 page 562
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520842.01- Mid Axle CDL Pressure Very Low 11
The middle cross axle differential lock (CDL) pressure is too low.
Front Axle CDL Pressure Very Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to next check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other front CDL diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to next check. ( 3 ) Component Check
Action: Ignition OFF. Disconnect the middle axle differential lock pressure sensor (B59). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance across pins A and B on the middle axle differential lock pressure sensor (B59). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to next check. NO:Replace pressure sensor. ( 4 ) CDL Pressure Check
Action: Check mid axle CDL pressure and adjust if necessary. See Cross-Axle Differential Lock (CDL) Pressure Test and Adjustment . (Group 9020-25.) Clear diagnostic trouble codes (DTCs) and test CDL operation. Is DTC 520842.01 still present?
<- Go to Section TOC
Section 9001 page 563
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Diagnose axle low pressure. See TEAMMATE™ V 1500 Series Axle 370E, 410E, 460E Series Outboard Planetary Axles . (CTM115319.) NO:Checks complete.
<- Go to Section TOC
Section 9001 page 564
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520845.00- Rear Axle CDL Pressure Very High 11
The rear cross axle differential lock (CDL) pressure is too high.
Rear Axle CDL Pressure Very High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to next check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other rear CDL diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to next check. ( 3 ) Component Check
Action: Ignition OFF. Disconnect the rear axle differential lock pressure sensor (B60). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance across pins A and B on the rear axle differential lock pressure sensor (B60). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to next check. NO:Replace pressure sensor. ( 4 ) CDL Pressure Check
Action: Check rear axle CDL pressure and adjust if necessary. See Cross-Axle Differential Lock (CDL) Pressure Test and Adjustment . (Group 9020-25.) Clear diagnostic trouble codes (DTCs) and test CDL operation. Is DTC 520845.00 still present?
<- Go to Section TOC
Section 9001 page 565
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Diagnose axle high pressure. See TEAMMATE™ V 1500 Series Axle 370E, 410E, 460E Series Outboard Planetary Axles . (CTM115319.) NO:Checks complete.
<- Go to Section TOC
Section 9001 page 566
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520845.01- Rear Axle CDL Pressure Very Low 11
The rear cross axle differential lock (CDL) pressure is too low.
Rear Axle CDL Pressure Very Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to next check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other rear CDL diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to next check. ( 3 ) Component Check
Action: Ignition OFF. Disconnect the rear axle differential lock pressure sensor (B60). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance across pins A and B on the rear axle differential lock pressure sensor (B60). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to next check. NO:Replace pressure sensor. ( 4 ) CDL Pressure Check
Action: Check rear axle CDL pressure and adjust if necessary. See Cross-Axle Differential Lock (CDL) Pressure Test and Adjustment . (Group 9020-25.) Clear diagnostic trouble codes (DTCs) and test CDL operation. Is DTC 520845.01 still present?
<- Go to Section TOC
Section 9001 page 567
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Diagnose axle low pressure. See TEAMMATE™ V 1500 Series Axle 370E, 410E, 460E Series Outboard Planetary Axles . (CTM115319.) NO:Checks complete.
<- Go to Section TOC
Section 9001 page 568
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520847.16- Body Down Solenoid Moderately High 11
The dump body down control solenoid low side driver is short to ground.
Body Down Solenoid Moderately High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body down control solenoid (Y23). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on dump body down control solenoid (Y23). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Dump body down control solenoid (Y23) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body down control solenoid (Y23). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check circuit R49 BLK for ground at pin 2 on dump body down solenoid (Y23) connector. Is voltage present?
Result: YES:Circuit R49 BLK is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect dump body down control solenoid (Y23). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin H3 (circuit R49 BLK) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
Section 9001 page 569
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit R49 BLK is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 570
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520847.17- Body Down Solenoid Slightly Low 11
The dump body down control solenoid low side driver circuit is open.
Body Down Solenoid Slightly Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body down control solenoid (Y23). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on dump body down control solenoid (Y23). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Dump body down control solenoid (Y23) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect dump body down control solenoid (Y23). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R49 BLK for continuity between pin 2 on dump body down control solenoid (Y23) connector and pin H3 on CCU connector (X21). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 571
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520847.18- Body Down Solenoid Moderately Low 11
The dump body down control solenoid low side driver is short to power.
Body Down Solenoid Moderately Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body down control solenoid (Y23). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on dump body down control solenoid (Y23). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Dump body down control solenoid (Y23) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body down control solenoid (Y23). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit R49 BLK for voltage at pin 2 on dump body down control solenoid (Y23) connector. Is voltage present?
Result: YES:Circuit R49 BLK is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect dump body down control solenoid (Y23). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 572
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin H3 (circuit R49 BLK) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit R49 BLK is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 573
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520848.03- Front CDL Solenoid Voltage High 11
The front cross axle differential lock (CDL) circuit is short to power.
Front CDL Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Disconnect front axle differential lock pressure regulating solenoid (Y55) and front axle differential lock apply solenoid (Y52). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check circuit H14 GRN for voltage at front axle differential lock pressure regulating solenoid (Y55) and front axle differential lock apply solenoid (Y52) harness connectors. Is voltage present?
Result: YES:Circuit H14 GRN is short to power. Repair or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect front axle differential lock pressure regulating solenoid (Y55) and front axle differential lock apply solenoid (Y52). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin D1 (circuit H14 GRN) of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H14 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Front Frame Harness (W2) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 574
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520848.05- Front CDL Solenoid Current Low 11
The front cross axle differential lock (CDL) circuit is open.
Front CDL Solenoid Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check—Front Axle Differential Lock Apply Solenoid. ( 2 ) Component Check—Front Axle Differential Lock Apply Solenoid
Action: Ignition OFF. Disconnect front axle differential lock apply solenoid (Y52). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance between terminals on front axle differential lock apply solenoid (Y52). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Component Check—Front Axle Differential Lock Pressure Regulating Solenoid. NO:Front axle differential apply lock solenoid (Y52) malfunction. Replace solenoid. ( 3 ) Component Check—Front Axle Differential Lock Pressure Regulating Solenoid
Action: Ignition OFF. Disconnect front axle differential lock pressure regulating solenoid (Y55). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance between terminals on front axle differential lock pressure regulating solenoid (Y55). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Front axle differential lock pressure regulating solenoid (Y55) malfunction. Replace solenoid. ( 4 ) Open Circuit Check
Action: Disconnect front axle differential regulating solenoid (Y55) and front axle differential apply solenoid (Y52). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 575
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check circuit H14 GRN for continuity between pin D1 of CCU connector (X21) and pin 1 on front axle differential apply solenoid (Y52). Check circuit H14 GRN for continuity between pin D1 of CCU connector (X21) and pin 1 on front axle differential regulating solenoid (Y55). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit H14 GRN is open. Repair or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 576
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520848.06- Front CDL Solenoid Current High 11
The front cross axle differential lock (CDL) circuit is short to ground.
Front CDL Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check—Front Axle Differential Lock Apply Solenoid. ( 2 ) Component Check—Front Axle Differential Lock Apply Solenoid
Action: Ignition OFF. Disconnect front axle differential lock apply solenoid (Y52). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance between terminals on front axle differential lock apply solenoid (Y52). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Component Check—Front Axle Differential Lock Pressure Regulating Solenoid. NO:Front axle differential lock apply solenoid (Y52) malfunction. Replace solenoid. ( 3 ) Component Check—Front Axle Differential Lock Pressure Regulating Solenoid
Action: Ignition OFF. Disconnect front axle differential lock pressure regulating solenoid (Y55). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance between terminals on front axle differential lock pressure regulating solenoid (Y55). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Front axle differential lock pressure regulating solenoid (Y55) malfunction. Replace solenoid. ( 4 ) Short Circuit Check
Action: Ignition OFF Disconnect front axle differential lock pressure regulating solenoid (Y55) and front axle differential lock apply solenoid (Y52). See Front Frame Harness (W2) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 577
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Ignition ON. Check circuit H14 GRN for ground at front axle differential lock pressure regulating solenoid (Y55) and front axle differential lock apply solenoid (Y52) harness connectors. Is ground present?
Result: YES:Circuit H14 GRN is short to ground. Repair or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 5 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect front axle differential lock pressure regulating solenoid (Y55) and front axle differential lock apply solenoid (Y52). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin D1 (circuit H14 GRN) of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H14 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Front Frame Harness (W2) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 578
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520851.03- Middle CDL Solenoid Voltage High 11
The middle cross axle differential lock (CDL) circuit is short to power.
Middle CDL Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Disconnect middle axle differential lock pressure regulating solenoid (Y56) and middle axle differential lock apply solenoid (Y53). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check circuit H03 GRN for voltage at middle axle differential lock pressure regulating solenoid (Y56) and middle axle differential lock apply solenoid (Y53) harness connectors. Is voltage present?
Result: YES:Circuit H03 GRN is short to power. Repair or replace harness. See Rear Frame Harness (W12) Component Location . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect middle axle differential lock pressure regulating solenoid (Y56) and middle axle differential lock apply solenoid (Y53). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 41 (circuit H03 GRN) of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H03 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Rear Frame Harness (W12) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 579
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520851.05- Middle CDL Solenoid Current Low 11
The middle cross axle differential lock (CDL) circuit is open.
Middle CDL Solenoid Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check—Middle Axle Differential Lock Apply Solenoid. ( 2 ) Component Check—Middle Axle Differential Lock Apply Solenoid
Action: Ignition OFF. Disconnect middle axle differential lock apply solenoid (Y53). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance between terminals on middle axle differential lock apply solenoid (Y53). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Component Check—Middle Axle Differential Lock Pressure Regulating Solenoid. NO:Middle axle differential apply lock solenoid (Y53) malfunction. Replace solenoid. ( 3 ) Component Check—Middle Axle Differential Lock Pressure Regulating Solenoid
Action: Ignition OFF. Disconnect middle axle differential lock pressure regulating solenoid (Y56). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance between terminals on middle axle differential lock pressure regulating solenoid (Y56). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Middle axle differential lock pressure regulating solenoid (Y56) malfunction. Replace solenoid. ( 4 ) Open Circuit Check
Action: Disconnect middle axle differential regulating solenoid (Y56) and middle axle differential apply solenoid (Y53). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 580
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check circuit H03 GRN for continuity between pin 41 of CCU connector (X22) and pin 1 on middle axle differential apply solenoid (Y53). Check circuit H03 GRN for continuity between pin 41 of CCU connector (X22) and pin 1 on middle axle differential regulating solenoid (Y56). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit H03 GRN is open. Repair or replace harness. See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 581
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520851.06- Middle CDL Solenoid Current High 11
The middle cross axle differential lock (CDL) circuit is short to ground.
Middle CDL Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check—Middle Axle Differential Lock Apply Solenoid. ( 2 ) Component Check—Middle Axle Differential Lock Apply Solenoid
Action: Ignition OFF. Disconnect middle axle differential lock apply solenoid (Y53). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance between terminals on middle axle differential lock apply solenoid (Y53). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Component Check—Middle Axle Differential Lock Pressure Regulating Solenoid. NO:Middle axle differential lock apply solenoid (Y53) malfunction. Replace solenoid. ( 3 ) Component Check—Middle Axle Differential Lock Pressure Regulating Solenoid
Action: Ignition OFF. Disconnect middle axle differential lock pressure regulating solenoid (Y56). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance between terminals on middle axle differential lock pressure regulating solenoid (Y56). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Middle axle differential lock pressure regulating solenoid (Y56) malfunction. Replace solenoid. ( 4 ) Short Circuit Check
Action: Ignition OFF. Disconnect middle axle differential lock pressure regulating solenoid (Y56) and middle axle differential lock apply solenoid (Y53). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 582
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Ignition ON. Check circuit H03 GRN for ground at middle axle differential lock pressure regulating solenoid (Y56) and middle axle differential lock apply solenoid (Y53) harness connectors. Is ground present?
Result: YES:Circuit H03 GRN is short to ground. Repair or replace harness. See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 5 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect middle axle differential lock pressure regulating solenoid (Y56) and middle axle differential lock apply solenoid (Y53). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 41 (circuit H14 GRN) of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H03 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Rear Frame Harness (W12) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 583
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520852.03- Rear CDL Solenoid Voltage High 11
The rear cross axle differential lock (CDL) circuit is short to power.
Rear CDL Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Disconnect rear axle differential lock pressure regulating solenoid (Y57) and rear axle differential lock apply solenoid (Y54). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Check circuit H03 GRN for voltage at rear axle differential lock pressure regulating solenoid (Y57) and rear axle differential lock apply solenoid (Y54) harness connectors. Is voltage present?
Result: YES:Circuit H03 GRN is short to power. Repair or replace harness. See Rear Frame Harness (W12) Component Location . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect rear axle differential lock pressure regulating solenoid (Y57) and rear axle differential lock apply solenoid (Y54). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 41 (circuit H03 GRN) of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H03 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Rear Frame Harness (W12) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 584
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520852.05- Rear CDL Solenoid Current Low 11
The rear cross axle differential lock (CDL) circuit is open.
Rear CDL Solenoid Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check—Rear Axle Differential Lock Apply Solenoid. ( 2 ) Component Check—Rear Axle Differential Lock Apply Solenoid
Action: Ignition OFF. Disconnect rear axle differential lock apply solenoid (Y54). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance between terminals on rear axle differential lock apply solenoid (Y54). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Component Check—Rear Axle Differential Lock Pressure Regulating Solenoid. NO:Rear axle differential apply lock solenoid (Y54) malfunction. Replace solenoid. ( 3 ) Component Check—Rear Axle Differential Lock Pressure Regulating Solenoid
Action: Ignition OFF. Disconnect rear axle differential lock pressure regulating solenoid (Y57). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance between terminals on rear axle differential lock pressure regulating solenoid (Y57). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Rear axle differential lock pressure regulating solenoid (Y57) malfunction. Replace solenoid. ( 4 ) Open Circuit Check
Action: Disconnect rear axle differential regulating solenoid (Y57) and rear axle differential apply solenoid (Y54). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 585
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check circuit H03 GRN for continuity between pin 41 of CCU connector (X22) and pin 1 on rear axle differential apply solenoid (Y54). Check circuit H03 GRN for continuity between pin 41 of CCU connector (X22) and pin 1 on rear axle differential regulating solenoid (Y57). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit H03 GRN is open. Repair or replace harness. See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 586
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520852.06- Rear CDL Solenoid Current High 11
The rear cross axle differential lock (CDL) circuit is short to ground.
Rear CDL Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check—Rear Axle Differential Lock Apply Solenoid. ( 2 ) Component Check—Rear Axle Differential Lock Apply Solenoid
Action: Ignition OFF. Disconnect rear axle differential lock apply solenoid (Y54). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance between terminals on rear axle differential lock apply solenoid (Y54). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Component Check—Rear Axle Differential Lock Pressure Regulating Solenoid. NO:Rear axle differential lock apply solenoid (Y54) malfunction. Replace solenoid. ( 3 ) Component Check—Rear Axle Differential Lock Pressure Regulating Solenoid
Action: Ignition OFF. Disconnect rear axle differential lock pressure regulating solenoid (Y57). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance between terminals on rear axle differential lock pressure regulating solenoid (Y57). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Rear axle differential lock pressure regulating solenoid (Y57) malfunction. Replace solenoid. ( 4 ) Short Circuit Check
Action: Ignition OFF. Disconnect rear axle differential lock pressure regulating solenoid (Y57) and rear axle differential lock apply solenoid (Y54). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 587
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Ignition ON. Check circuit H03 GRN for ground at rear axle differential lock pressure regulating solenoid (Y57) and rear axle differential lock apply solenoid (Y54) harness connectors. Is ground present?
Result: YES:Circuit H03 GRN is short to ground. Repair or replace harness. See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 5 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect rear axle differential lock pressure regulating solenoid (Y57) and rear axle differential lock apply solenoid (Y54). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 41 (circuit H14 GRN) of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H03 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Rear Frame Harness (W12) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 588
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520854.03- Body Heat Solenoid Voltage High 11
The dump body heat solenoid high side driver circuit is short to power.
Body Heat Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body heat solenoid (Y7). See Hydraulic Tank Harness (W8) Component Location . (Group 9015-10.) Ignition ON. Dump body heat OFF. Check circuit H18 GRN for voltage at pin 1 on dump body heat solenoid (Y7) connector. Is voltage present?
Result: YES:Circuit H18 GRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Tank Harness (W8) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect dump body heat solenoid (Y7). See Hydraulic Tank Harness (W8) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 43 (circuit H18 GRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H18 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Tank Harness (W8) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 589
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520854.05- Body Heat Solenoid Current Low 11
The dump body heat solenoid high side driver circuit is open.
Body Heat Solenoid Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body heat solenoid (Y7). See Hydraulic Tank Harness (W8) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on dump body heat solenoid (Y7). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Dump body heat solenoid (Y7) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect dump body heat solenoid (Y7). See Hydraulic Tank Harness (W8) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H18 GRN for continuity between pin 1 on dump body heat solenoid (Y7) connector and pin 43 on CCU connector (X22). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Tank Harness (W8) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 590
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520854.06- Body Heat Solenoid Current High 11
The dump body heat solenoid high side driver circuit is short to ground.
Body Heat Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body heat solenoid (Y7). See Hydraulic Tank Harness (W8) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on dump body heat solenoid (Y7). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Dump body heat solenoid (Y7) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body heat solenoid (Y7). See Hydraulic Tank Harness (W8) Component Location . (Group 9015-10.) Dump body heat OFF. Check circuit H18 GRN for ground at pin 1 on dump body heat solenoid (Y7) connector. Is ground present?
Result: YES:Circuit H18 GRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Tank Harness (W8) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect dump body heat solenoid (Y7). See Hydraulic Tank Harness (W8) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 591
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin 43 (circuit H18 GRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H18 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Tank Harness (W8) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 592
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520855.03- Body Lever Solenoid Voltage High 11
The dump body lever detent magnet high side driver circuit is short to power.
Body Lever Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Dump Body Control and Gear Limit Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: →NOTE: The dump body lever connector contains wiring for the dump body lever detent magnet (Y30) and dump body lever position sensor (B25). For location of magnet (Y30) and sensor (B25), see Cab Harness (W3) Component Location . (Group 9015-10.) Ignition OFF. Disconnect dump body lever detent magnet (Y30). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit H43 GRN for voltage at pin 6 on dump body lever connector. Is voltage present?
Result: YES:Circuit H43 GRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect dump body lever detent magnet (Y30). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 42 (circuit H42 GRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H42 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). <- Go to Section TOC
Section 9001 page 593
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
<- Go to Section TOC
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Section 9001 page 594
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520855.05- Body Lever Solenoid Current Low 11
The dump body lever detent magnet high side driver circuit is open.
Body Lever Solenoid Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Dump Body Control and Gear Limit Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: →NOTE: The dump body lever connector contains wiring for the dump body lever detent magnet (Y30) and dump body lever position sensor (B25). For location of magnet (Y30) and sensor (B25), see Cab Harness (W3) Component Location . (Group 9015-10.) Ignition OFF. Disconnect dump body lever detent magnet (Y30). See Cab Harness (W3) Component Location . (Group 9015-10.) Measure dump body lever detent magnet resistance between terminals 5 and 6 on dump body lever connector. Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Dump body lever detent magnet (Y30) malfunction. Replace dump body lever detent magnet. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect dump body lever detent magnet (Y30). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 6 (circuit H43 GRN) on dump body lever detent magnet (Y30) and pin 42 (circuit H42 GRN) on CCU connector (X22). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 595
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520855.06- Body Lever Solenoid Current High 11
The dump body lever detent magnet high side driver circuit is short to ground.
Body Lever Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Dump Body Control and Gear Limit Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: →NOTE: The dump body lever connector contains wiring for the dump body lever detent magnet (Y30) and dump body lever position sensor (B25). For location of magnet (Y30) and sensor (B25), see Cab Harness (W3) Component Location . (Group 9015-10.) Ignition OFF. Disconnect dump body lever detent magnet (Y30). See Cab Harness (W3) Component Location . (Group 9015-10.) Measure dump body lever detent magnet resistance between terminals 5 and 6 on bump body lever connector. Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Dump body lever detent magnet (Y30) malfunction. Replace dump body lever detent magnet. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body lever detent magnet (Y30). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H43 GRN for ground at pin 6 on dump body lever connector. Is ground present?
Result: YES:Circuit H43 GRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
<- Go to Section TOC
Section 9001 page 596
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Action: Turn battery disconnect switch OFF. Disconnect dump body lever detent magnet (Y30). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 42 (circuit H42 GRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H42 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 597
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520859.03- Yellow OBW Light Voltage High 11
The yellow on board weighing (OBW) light circuit is short to power.
Yellow OBW Light Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 12 volts to terminal 1 and ground to terminal 4 to on board weighing (OBW) lights connector (X25). Does light function?
Result: YES:Go to Short Circuit Check. NO:On board weighing (OBW) light (H12) malfunction. Replace on board weighing (OBW) light. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. On board weighing OFF. Check circuit L05 BRN for voltage at pin 1 on connector (X25). Is voltage present?
Result: YES:Circuit L05 BRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 598
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin J1 (circuit L05 BRN) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L05 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 599
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520859.05- Yellow OBW Light Current Low 11
The yellow on board weighing (OBW) light circuit is open.
Yellow OBW Light Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 12 volts to terminal 1 and ground to terminal 4 to on board weighing (OBW) lights connector (X25). Does light function?
Result: YES:Go to Open Circuit Check. NO:On board weighing (OBW) light (H12) malfunction. Replace on board weighing (OBW) light. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L05 BRN for continuity between pin 1 on OBW lights connector (X25) and pin J1 on CCU connector (X21). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 600
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520859.06- Yellow OBW Light Current High 11
The Yellow on board weighing (OBW) light circuit is short to ground.
Yellow OBW Light Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 12 volts to terminal 1 and ground to terminal 4 to on board weighing (OBW) lights connector (X25). Does light function?
Result: YES:Go to Short Circuit Check. NO:On board weighing (OBW) light (H12) malfunction. Replace on board weighing (OBW) light. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L05 BRN for ground at pin 1 on connector (X25). Is ground present?
Result: YES:Circuit L05 BRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin J1 (circuit L05 BRN) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 601
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit L05 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 602
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520869.03- Green OBW Light Voltage High 11
The green on board weighing (OBW) light circuit is short to power.
Green OBW Light Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 12 volts to terminal 2 and ground to terminal 4 to on board weighing (OBW) lights connector (X25). Does light function?
Result: YES:Go to Short Circuit Check. NO:On board weighing (OBW) light (H13) malfunction. Replace on board weighing (OBW) light. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. On board weighing OFF. Check circuit L28 BRN for voltage at pin 2 on connector (X25). Is voltage present?
Result: YES:Circuit L28 BRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 603
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin C4 (circuit L28 BRN) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L28 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 604
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520869.05- Green OBW Light Current Low 11
The green on board weighing (OBW) light circuit is open.
Green OBW Light Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 12 volts to terminal 2 and ground to terminal 4 to on board weighing (OBW) lights connector (X25). Does light function?
Result: YES:Go to Open Circuit Check. NO:On board weighing (OBW) light (H13) malfunction. Replace on board weighing (OBW) light. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L28 BRN for continuity between pin 2 on OBW lights connector (X25) and pin C4 on CCU connector (X21). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 605
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520869.06- Green OBW Light Current High 11
The green on board weighing (OBW) light circuit is short to ground.
Green OBW Light Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 12 volts to terminal 2 and ground to terminal 4 to on board weighing (OBW) lights connector (X25). Does light function? (Group 9015-20.)
Result: YES:Go to Short Circuit Check. NO:On board weighing (OBW) light (H13) malfunction. Replace on board weighing (OBW) light. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L28 BRN for ground at pin 2 on connector (X25). Is voltage present?
Result: YES:Circuit L28 BRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin C4 (circuit L28 BRN) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 606
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit L28 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 607
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520877.03- Red OBW Light Voltage High 11
The red on board weighing (OBW) light circuit is short to power.
Red OBW Light Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 12 volts to terminal 3 and ground to terminal 4 to on board weighing (OBW) lights connector (X25). Does light function?
Result: YES:Go to Short Circuit Check. NO:On board weighing (OBW) light (H14) malfunction. Replace on board weighing (OBW) light. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. On board weighing OFF. Check circuit L15 BRN for voltage at pin 3 on connector (X25). Is voltage present?
Result: YES:Circuit L15 BRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 608
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin 47 (circuit L15 BRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L15 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 609
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520877.05- Red OBW Light Current Low 11
The red on board weighing (OBW) light circuit is open.
Red OBW Light Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 12 volts to terminal 3 and ground to terminal 4 to on board weighing (OBW) lights connector (X25). Does light function?
Result: YES:Go to Open Circuit Check. NO:On board weighing (OBW) light (H14) malfunction. Replace on board weighing (OBW) light. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L15 BRN for continuity between pin 3 on OBW lights connector (X25) and pin 47 on CCU connector (X22). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 610
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520877.06- Red OBW Light Current High 11
The red on board weighing (OBW) light circuit is short to ground.
Red OBW Light Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 12 volts to terminal 3 and ground to terminal 4 to on board weighing (OBW) lights connector (X25). Does light function?
Result: YES:Go to Short Circuit Check. NO:On board weighing (OBW) light (H14) malfunction. Replace on board weighing (OBW) light. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L15 BRN for ground at pin 3 on connector (X25). Is ground present?
Result: YES:Circuit L15 BRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect on board weighing (OBW) lights connector (X25). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 47 (circuit L15 BRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 611
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit L15 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 612
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520878.03- Axle Cooling Cutoff Solenoid Voltage High 11
The axle cooling cut-off solenoid high side driver circuit is short to power.
Axle Cooling Cutoff Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect axle cooling cut-off solenoid (Y2). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit H20 GRN for voltage at pin 1 of axle cooling cut-off solenoid (Y2) harness connector. Is voltage present?
Result: YES:Wire H20 GRN is short to power. Repair circuit or replace harness. See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Ignition OFF. Disconnect axle cooling cut-off solenoid (Y2). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 31 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H20 GRN is short to circuit with continuity indicated. Repair or replace circuits. See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 613
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520878.05- Axle Cooling Cutoff Solenoid Current Low 11
The axle cooling cut-off solenoid high side driver circuit is open.
Axle Cooling Cutoff Solenoid Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect axle cooling cut-off solenoid (Y2). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Axle cooling cut-off solenoid (Y2) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect axle cooling cut-off solenoid (Y2). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H20 GRN for continuity between pin 31 of CCU connector (X22) harness connector and pin 1 of axle cooling cutoff solenoid (Y2) harness connector. Check circuit G13 BLK for continuity between pin 2 of axle cooling cutt-off solenoid (Y2) harness connector and machine ground. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 614
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520878.06- Axle Cooling Cutoff Solenoid Current High 11
The axle cooling cut-off solenoid high side driver circuit is short to ground.
Axle Cooling Cutoff Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect axle cooling cut-off solenoid (Y2). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Axle cooling cut-off solenoid (Y2) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect axle cooling cut-off solenoid (Y2). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H20 GRN for ground at pin 1 on axle cooling cut-off solenoid (Y2) harness connector. Is ground present?
Result: YES:Circuit H20 GRN is short to ground. Repair circuit or replace harness. See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect axle cooling cut-off solenoid (Y2). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 31 (circuit H20 GRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit H20 GRN is short to circuit with continuity indicated. Repair or replace circuit. See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 616
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520878.16- Axle Cooling Cutoff Solenoid Moderately High 11
The axle cooling cut-off solenoid high side driver circuit is short to ground.
Axle Cooling Cutoff Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect axle cooling cut-off solenoid (Y2). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Axle cooling cut-off solenoid (Y2) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect axle cooling cut-off solenoid (Y2). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H20 GRN for ground at pin 1 on axle cooling cut-off solenoid (Y2) harness connector. Is ground present?
Result: YES:Circuit H20 GRN is short to ground. Repair circuit or replace harness. See Hydraulic Harness (W13) Component Location . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect axle cooling cut-off solenoid (Y2). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 31 (circuit H20 GRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
Section 9001 page 617
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit H20 GRN is short to circuit with continuity indicated. Repair or replace circuit. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 618
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520878.17- Axle Cooling Cutoff Solenoid Slightly Low 11
The axle cooling cut-off solenoid high side driver circuit is open.
Axle Cooling Cutoff Solenoid Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect axle cooling cut-off solenoid (Y2). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Axle cooling cut-off solenoid (Y2) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect axle cooling cut-off solenoid (Y2). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H20 GRN for continuity between pin 31 of CCU connector (X22) harness connector and pin 1 of axle cooling cutoff solenoid (Y2) harness connector. Check circuit G13 BLK for continuity between pin 2 of axle cooling cutt-off solenoid (Y2) harness connector and machine ground. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 619
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520878.18- Axle Cooling Cutoff Solenoid Moderately Low 11
The axle cooling cut-off solenoid high side driver circuit is short to power.
Axle Cooling Cutoff Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect axle cooling cut-off solenoid (Y2). See Articulation Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit H20 GRN for voltage at pin 1 of axle cooling cut-off solenoid (Y2) harness connector. Is voltage present?
Result: YES:Wire H20 GRN is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Ignition OFF. Disconnect axle cooling cut-off solenoid (Y2). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 31 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H20 GRN is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 620
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520880.03- Fan 2 Cutoff Solenoid Voltage High 11
The right side fan cut-off solenoid high side driver circuit is short to power.
Fan 2 Cutoff Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect right side fan cut-off solenoid (Y11). See Articulation Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit H09 GRN for voltage at pin 1 of right side fan cut-off solenoid (Y11) harness connector. Is voltage present?
Result: YES:Circuit H09 GRN is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Ignition OFF. Disconnect right side fan cut-off solenoid (Y11). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 7 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H09 GRN is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 621
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520880.05- Fan 2 Cutoff Solenoid Current Low 11
The right side fan cut-off solenoid high side driver circuit is open.
Fan 2 Cutoff Solenoid Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right side fan cut-off solenoid (Y11). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Right side fan cut-off solenoid (Y11) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect right side fan cut-off solenoid (Y11). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H09 GRN for continuity between pin 7 of CCU connector (X22) harness connector and pin A of right side fan cutoff solenoid (Y11) harness connector. Check circuit G13 BLK for continuity between pin B of right side fan cut-off solenoid (Y11) harness connector and machine ground. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 622
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520880.06- Fan 2 Cutoff Solenoid Current High 11
The right side fan cut-off solenoid high side driver circuit is short to ground.
Fan 2 Cutoff Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right side fan cut-off solenoid (Y11). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Right side fan cut-off solenoid (Y11) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right side fan cut-off solenoid (Y11). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H09 GRN for ground at pin A on right side fan cut-off solenoid (Y11) harness connector. Is ground present?
Result: YES:Circuit H09 GRN is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect right side fan cut-off solenoid (Y11). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 7 (circuit H09 GRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
Section 9001 page 623
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit H09 GRN is short to circuit with continuity indicated. Repair or replace circuit. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 624
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520886.03- Load Hold Solenoid Voltage High 11
The load holding pilot solenoid high side driver circuit is short to power.
Load Hold Solenoid Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect load holding pilot solenoid (Y25). See Articulation Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit H21 GRN for voltage at pin 1 of load holding pilot solenoid (Y25) harness connector. Is voltage present?
Result: YES:Wire H21 GRN is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Ignition OFF. Disconnect load holding pilot solenoid (Y25). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 29 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H21 GRN is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 625
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520886.05- Load Hold Solenoid Current Low 11
The load holding pilot solenoid high side driver circuit is open.
Load Hold Solenoid Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect load holding pilot solenoid circuit (Y25). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Load holding pilot solenoid circuit (Y25) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect load holding pilot solenoid circuit (Y25). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H21 GRN for continuity between pin 29 of CCU connector (X22) harness connector and pin 1 of load holding pilot solenoid circuit (Y25) harness connector. Check circuit G12 BLK for continuity between pin 2 of load holding pilot solenoid circuit (Y25) harness connector and machine ground. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 626
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520886.06- Load Hold Solenoid Current High 11
The load holding pilot solenoid high side driver circuit is short to ground.
Load Hold Solenoid Current High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect load holding pilot solenoid circuit (Y25). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Load holding pilot solenoid circuit (Y25) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect load holding pilot solenoid circuit (Y25). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H21 GRN for ground at pin 1 on load holding pilot solenoid circuit (Y25) harness connector. Is ground present?
Result: YES:Circuit H21 GRN is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect load holding pilot solenoid circuit (Y25). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 29 (circuit H21 GRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
Section 9001 page 627
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit H21 GRN is short to circuit with continuity indicated. Repair or replace circuit. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 628
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520889.03- Left Strut Position Sensor Voltage High 11
The left side height sensor is short to power.
Left Strut Position Sensor Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left side height sensor (B11). See Articulation Harness (W9) Component Location . (Group 9015-10.) Measure resistance between terminals C and A on left side height sensor (B11). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Left side height sensor (B11) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left side height sensor (B11). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit M22 PUR for voltage at pin B on left side height sensor (B11) harness connector. Is voltage present?
Result: YES:Circuit M22 PUR is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect left side height sensor (B11). See Articulation Harness (W9) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 629
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 25 (circuit M22 PUR) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit M22 PUR is short to circuit that indicated continuity. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 630
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520889.04- Left Strut Position Sensor Voltage Low 11
The left side height sensor is short to ground.
Left Strut Position Sensor Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left side height sensor (B11). See Articulation Harness (W9) Component Location . (Group 9015-10.) Measure resistance between terminals C and A on left side height sensor (B11). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Left side height sensor (B11) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left side height sensor (B11). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit M22 PUR for ground at pin B on left side height sensor (B11) harness connector. Is ground present?
Result: YES:Circuit M22 PUR is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect left side height sensor (B11). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 631
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin 25 (circuit M22 PUR) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit M22 PUR is short to circuit that indicated continuity. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 632
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520899.03- Right Strut Position Sensor Voltage High 11
The right side height sensor is short to power.
Right Strut Position Sensor Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right side height sensor (B10). See Articulation Harness (W9) Component Location . (Group 9015-10.) Measure resistance between terminals C and A on right side height sensor (B10). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Right side height sensor (B10) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right side height sensor (B10). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit M10 PUR for voltage at pin B on right side height sensor (B10) harness connector. Is voltage present?
Result: YES:Circuit M10 PUR is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect right side height sensor (B10). See Articulation Harness (W9) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 633
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 37 (circuit M10 PUR) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit M10 PUR is short to circuit that indicated continuity. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 634
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520899.04- Right Strut Position Sensor Voltage Low 11
The right side height sensor is short to ground.
Right Strut Position Sensor Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right side height sensor (B10). See Articulation Harness (W9) Component Location . (Group 9015-10.) Measure resistance between terminals C and A on right side height sensor (B10). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Right side height sensor (B10) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right side height sensor (B10). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit M10 PUR for ground at pin B on right side height sensor (B10) harness connector. Is voltage present?
Result: YES:Circuit M10 PUR is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect right side height sensor (B10). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 635
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin 37 (circuit M10 PUR) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit M10 PUR is short to circuit that indicated continuity. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 636
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520900.03- Body Pressure Reducing Solenoid Voltage High 11
The body dump reduction solenoid high side driver circuit is short to power.
Body Pressure Reducing Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body reduction solenoid (Y26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit H19 GRN for voltage at pin 1 of dump body reducing solenoid (Y26) harness connector. Is voltage present?
Result: YES:Wire H19 GRN is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Ignition OFF. Disconnect dump body reduction solenoid (Y26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin F4 of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H19 GRN is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 637
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520900.05- Body Pressure Reducing Solenoid Current Low 11
The dump body reduction high side driver circuit is open.
Body Pressure Reducing Solenoid Current Low Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body reduction solenoid (Y26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Dump body reduction solenoid (Y26) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect dump body reduction solenoid (Y26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H19 GRN for continuity between pin F4 of CCU connector (X21) harness connector and pin 1 of dump body reduction solenoid (Y26) harness connector. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 638
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520900.06- Body Pressure Reducing Solenoid Current High 11
The dump body reduction solenoid high side driver circuit is short to ground.
Body Pressure Reducing Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body reduction solenoid (Y26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Dump body reduction solenoid (Y26) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body reduction solenoid (Y26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check circuit H19 GRN for ground at pin 1 of dump body reduction solenoid (Y26) harness connector. Is voltage present?
Result: YES:Wire H19 GRN is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect dump body reduction solenoid (Y26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin F4 of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated? <- Go to Section TOC
Section 9001 page 639
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit H19 GRN is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 640
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520900.16- Body Pressure Reducing Solenoid Moderately High 11
The dump body reduction solenoid low side driver circuit is short to ground.
Body Pressure Reducing Solenoid Moderately High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body reduction solenoid (Y26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Dump body reduction solenoid (Y26) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body reduction solenoid (Y26). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R47 BLK for ground at pin 2 on dump body reduction solenoid (Y26) harness connector. Is ground present?
Result: YES:Circuit R47 BLK is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect dump body reduction solenoid (Y26). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 641
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin 33 (circuit R47 BLK) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit R47 BLK is short to circuit that indicated continuity. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 642
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520900.17- Body Pressure Reducing Solenoid Slightly Low 11
The dump body reduction solenoid low side driver circuit is open.
Body Pressure Reducing Solenoid Slightly Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body reduction solenoid (Y26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Harness Check. NO:Dump body reduction solenoid (Y26) malfunction. Replace solenoid. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connector (X22). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect dump body reduction solenoid (Y26). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 33 (circuit R47 BLK) on CCU connector (X22) and pin 2 on solenoid (Y26) connector. Is continuity indicated?
Result: YES:Circuit that does not indicate continuity is open. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 643
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520900.18- Body Pressure Reducing Solenoid Moderately Low 11
The dump body reduction solenoid low side driver circuit is short to power.
Body Pressure Reducing Solenoid Moderately Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body reduction solenoid (Y26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Dump body reduction solenoid (Y26) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body reduction solenoid (Y26). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit R47 BLK for voltage at pin 2 on dump body reduction pilot solenoid (Y26) harness connector. Is volage present?
Result: YES:Circuit R47 BLK is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect dump body reduction solenoid (Y26). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 644
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin 33 (circuit R47 BLK) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit R47 BLK is short to circuit that indicated continuity. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 645
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520911.04- Service Light Switch Voltage Low 11
The service light switch circuit is short to ground.
Service Light Switch Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect service light switch (S6). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check continuity between pin A of service light switch (S6) and machine ground. Is continuity indicated?
Result: YES:Service light switch (S6) malfunction. Replace switch. NO:Go to Short Circuit Check. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect service light switch (S6). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check circuit L01 BRN for ground at pin A on service light switch (S6). Is ground present?
Result: YES:Circuit L01 BRN is short to ground. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect service light switch (S6). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 40 (circuit L01 BRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
<- Go to Section TOC
Section 9001 page 646
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit L01 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 647
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520913.03- Body Lever Position Sensor Voltage High 11
The body lever position sensor circuit is open or short to power.
Body Lever Position Sensor Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body control lever position sensor (B25). See Cab Harness (W3) Component Location . (Group 9015-10.) Measure resistance between terminals A and C on dump body control lever position sensor (B25). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Dump body control lever position sensor (B25) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body control lever position sensor (B25). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit J02 TAN for voltage at pin B on dump body control lever position sensor (B25) connector. Is voltage present?
Result: YES:Circuit J02 TAN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 4 ) Open Circuit Check
Action: Ignition OFF. Disconnect dump body control lever position sensor (B25). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 648
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check circuit J02 TAN for continuity between pin 1 on dump body control lever position sensor (B25) connector and pin 21 on CCU connector (X23). Check circuit G51 BLK for continuity between pin 5 on dump body control lever position sensor (B25) connector and frame ground. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit without continuity indicated is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 5 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect dump body control lever position sensor (B25). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 21 (circuit J02 TAN) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit J02 TAN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 649
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520913.04- Body Lever Position Sensor Voltage Low 11
The body lever position sensor circuit is short to ground.
Body Lever Position Sensor Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect dump body lever position sensor (B25). See Cab Harness (W3) Component Location . (Group 9015-10.) Measure resistance between terminals 1 and 2 on dump body lever position sensor (B25). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Dump body lever position sensor (B25) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body lever position sensor (B25). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit J02 TAN for ground at pin 3 on dump body lever position sensor (B25) connector. Is ground present?
Result: YES:Circuit J02 TAN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 650
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520914.03- Body Position Sensor Voltage High 11
The body dump position sensor circuit is open or short to power.
Body Position Sensor Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Perform Dump Body Position Sensor Test . (Group 9015-20.) Does sensor test good?
Result: YES:Go to Short Circuit Check. NO:Replace dump body position sensor (B6). ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body position sensor (B6). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Ignition ON. Check circuit M05 PUR for voltage at pin B on dump body position sensor (B6) connector. Is voltage present?
Result: YES:Circuit M05 PUR is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W7) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 4 ) Open Circuit Check
Action: Ignition OFF. Disconnect dump body position sensor (B6). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit M05 PUR for continuity between pin B on dump body position sensor (B6) connector and pin 33 on CCU connector (X23). Check circuit P22 RED for continuity between pin C on dump body position sensor (B6) connector and pin E2 on CCU connector <- Go to Section TOC
Section 9001 page 651
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
(X21). Check circuit R06 BLK for continuity between pin A on dump body position sensor (B6) connector and pin F2 on CCU connector (X21). Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuit without continuity indicated is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W7) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) ( 5 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect dump body position sensor (B6). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 33 (circuit M05 PUR) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit M05 PUR is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W7) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Go to Dump Body Sensor Calibration. ( 6 ) Dump Body Sensor Calibration
Action: Perform Dump Body Position Sensor Calibration . (Group 9015-20.) Is DTC 520914.03 still active?
Result: YES:Program chassis control unit (CCU). NO:Checks complete.
<- Go to Section TOC
Section 9001 page 652
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520914.04- Body Position Sensor Voltage Low 11
The body dump position circuit is short to ground.
Body Position Sensor Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Perform Dump Body Position Sensor Test . (Group 9015-20.) Does sensor test good?
Result: YES:Go to short Circuit Check. NO:Replace dump body position sensor (B6). ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect dump body position sensor (B6). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Ignition ON. Check circuit M05 PUR for ground at pin B on dump body position sensor (B6) connector. Is ground present?
Result: YES:Circuit M05 PUR is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W7) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Circuit Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect dump body position sensor (B6). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 33 (circuit M05 PUR) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 653
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit M05 PUR is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W7) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Go to Dump Body Sensor Calibration. ( 5 ) Dump Body Sensor Calibration
Action: Perform Dump Body Position Sensor Calibration . (Group 9015-20.) Is DTC 520914.03 still active?
Result: YES:Program chassis control unit (CCU). NO:Checks complete.
<- Go to Section TOC
Section 9001 page 654
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520915.03- IDL Solenoid Driver Solenoid Voltage High 44
The inter-axle differential lock (IDL) solenoid circuit is short to power.
IDL Solenoid Driver Solenoid Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation and Differential Lock Circuits Theory of Operation .(Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect IDL solenoid (Y70). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Measure resistance between pins A and B of solenoid (Y70. Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace inter-axle differential lock (IDL) solenoid (Y70). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0316 for voltage at pin 16 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0316 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 655
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 12 (circuit 0316) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0316 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 16 (circuit BRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 656
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520915.05- IDL Solenoid Driver Solenoid Current Low 44
The inter-axle differential lock (IDL) solenoid circuit is open.
IDL Solenoid Driver Solenoid Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation and See Differential Lock Circuits Theory of Operation (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Remove transmission solenoid cover plate. Disconnect inter-axle differential lock (IDL) solenoid (Y70). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check for resistance between pin A and pin B of inter-axle differential lock (IDL) solenoid (Y70). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Open Circuit Check. NO:Replace inter-axle differential lock (IDL) solenoid (Y70). ( 3 ) Open Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connector (X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check circuit 0316 for continuity between pin 12 of connector (X71) and pin 16 on harness (W4) side of connector (X72). Is continuity indicated?
Result: YES:Go to next check. NO:Circuit 0316 is open in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 657
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Action: Disconnect inter-axle differential lock (IDL) solenoid (Y70). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Check circuit BRN for continuity between pin 16 on harness (W5) side of connector (X72) and pin A on c inter-axle differential lock (IDL) solenoid (Y70) harness connector. Check circuit RED for continuity between pin 24 on harness (W5) side of connector (X72) and pin B on inter-axle differential lock (IDL) solenoid (Y70) harness connector. Is continuity indicated?
Result: YES:Program transmission control unit (TCU). NO:Circuit that does not indicate continuity is open in transmission control harness (W5). Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 658
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520915.06- IDL Solenoid Driver Solenoid Current High 44
The inter-axle differential lock (IDL) solenoid circuit is short to ground.
IDL Solenoid Driver Solenoid Current High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation and Differential Lock Circuits Theory of Operation .(Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Disconnect IDL solenoid (Y70). See Clutch Control Harness (W5) Component Location . (Group 9015-10.) Measure resistance between pins A and B of solenoid (Y70. Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to Short Circuit Check. NO:Replace inter-axle differential lock (IDL) solenoid (Y70). ( 3 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit 0316 for voltage at pin 16 on harness (W4) side of connector (X72). Is voltage present?
Result: YES:Circuit 0316 is short to power in transmission control harness (W4). Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect transmission control unit (TCU) connectors (X70 and X71). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 659
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect transmission control harness-to-transmission valve control harness connector (X72). See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) Check for continuity between pin 12 (circuit 0316) on TCU connector (X71) and all other pins on TCU connectors (X70 and X71). Is continuity indicated?
Result: YES:Circuit 0316 is short to circuit that indicated continuity. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) NO:Go to next check.
Action: Check for continuity between pin 16 (circuit BRN) on harness (W5) side of connector (X72) and all other pins on connector (X72). Is continuity indicated?
Result: YES:Circuit BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Clutch Control Harness (W5) Wiring Diagram . (Group 9015-10.) NO:Program transmission control unit (TCU).
<- Go to Section TOC
Section 9001 page 660
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520949.03- Left Strut Raise Solenoid Voltage High 11
The left strut up solenoid high side driver circuit is short to power.
Left Strut Raise Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40) and left strut down solenoid (Y41). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoids. See Electrical Component Specifications . (Group 9015-20.) Are solenoids within specification?
Result: YES:Go to Short Circuit Check. NO:Replace solenoids not within specification. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40). See Articulation Harness (W9) Component Location (Group 9015-10.) Ignition ON. Check circuit H29 GRN for voltage at pin 1 of left strut up solenoid (Y40) harness connector. Is voltage present?
Result: YES:Wire H29 GRN is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 661
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check circuit H29 GRN for continuity between pin 17 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H29 GRN is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 662
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520949.05- Left Strut Raise Solenoid Current Low 11
The left strut up solenoid high side driver circuit is open.
Left Strut Raise Solenoid Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40) and left strut down solenoid (Y41). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoids. See Electrical Component Specifications . (Group 9015-20.) Are solenoids within specification?
Result: YES:Go to Short Circuit Check. NO:Replace solenoids not within specification. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H29 GRN for continuity between pin 17 of CCU connector (X22) and pin 1 on left strut up solenoid (Y40). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 663
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520949.06- Left Strut Raise Solenoid Current High 11
The left strut up solenoid high side driver circuit is short to ground.
Left Strut Raise Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40) and left strut down solenoid (Y41). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoids. See Electrical Component Specifications . (Group 9015-20.) Are solenoids within specification?
Result: YES:Go to Short Circuit Check. NO:Replace solenoids not within specification. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check circuit H29 GRN for ground at pin 1 of left strut up solenoid (Y40) harness connector. Is ground present?
Result: YES:Wire H29 GRN is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 17 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 664
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit H29 GRN is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 665
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520949.16- Left Strut Raise Solenoid Moderately High 11
The left strut up solenoid low side driver circuit is short to ground.
Left Strut Raise Solenoid Moderately High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Left strut up solenoid (Y40) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check circuit R65 BLK for ground at pin 2 of left strut up solenoid (Y40) harness connector. Is ground present?
Result: YES:Wire R65 BLK is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R65 BLK for continuity between pin 48 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 666
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit R65 BLK is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 667
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520949.17- Left Strut Raise Solenoid Slightly Low 11
The left strut up solenoid low side driver circuit is open.
Left Strut Raise Solenoid Slightly Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Left strut up solenoid (Y40) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R65 BLK for continuity between pin 48 of CCU connector (X22) and pin 2 on left strut up solenoid (Y40). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 668
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520949.18- Left Strut Raise Solenoid Moderately Low 11
The left strut up solenoid low side driver circuit is short to power.
Left Strut Raise Solenoid Moderately Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Left strut up solenoid (Y40) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40). See Articulation Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit R65 BLK for voltage at pin 2 of left strut up solenoid (Y40) harness connector. Is voltage present?
Result: YES:Wire R65 BLK is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect left strut up solenoid (Y40). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R65 BLK for continuity between pin 48 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
Section 9001 page 669
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit R65 BLK is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 670
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520950.16- Left Strut Lower Solenoid Moderately High 11
The left strut down solenoid low side driver circuit is short to ground.
Left Strut Lower Solenoid Moderately High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left strut down solenoid (Y41). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Left strut down solenoid (Y41) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left strut down solenoid (Y41). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check circuit R57 BLK for ground at pin B of left strut down solenoid (Y41) harness connector. Is ground present?
Result: YES:Wire R57 BLK is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect left strut down solenoid (Y41). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R57 BLK for continuity between pin 11 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 671
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit R57 BLK is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 672
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520950.17- Left strut Lower Solenoid Slightly Low 11
The left strut down solenoid low side driver circuit is open.
Left strut Lower Solenoid Slightly Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left strut down solenoid (Y41). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Left strut down solenoid (Y41) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect left strut down solenoid (Y41). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R57 BLK for continuity between pin 11 of CCU connector (X22) and pin B on left strut down solenoid (Y41). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 673
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520950.18- Left Strut Lower Solenoid Moderately Low 11
The left strut down solenoid low side driver circuit is short to power.
Left Strut Lower Solenoid Moderately Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left strut down solenoid (Y41). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Left strut down solenoid (Y41) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left strut down solenoid (Y41). See Articulation Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit R57 BLK for voltage at pin B of left strut down solenoid (Y41) harness connector. Is voltage present?
Result: YES:Wire R57 BLK is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect left strut down solenoid (Y41). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R57 BLK for continuity between pin 11 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
Section 9001 page 674
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit R57 BLK is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 675
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520953.03- Right Strut Raise Solenoid Voltage High 11
The right strut up solenoid high side driver circuit is short to power.
Right Strut Raise Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38) and right strut down solenoid (Y39). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoids. See Electrical Component Specifications . (Group 9015-20.) Are solenoids within specification?
Result: YES:Go to Short Circuit Check. NO:Replace solenoids not within specification. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38). See Articulation Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit H27 GRN for voltage at pin 1 of right strut up solenoid (Y38) harness connector. Is voltage present?
Result: YES:Wire H27 GRN is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 676
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check circuit H27 GRN for continuity between pin 53 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H27 GRN is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 677
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520953.05- Right Strut Raise Solenoid Current Low 11
The right strut up solenoid high side driver circuit is open.
Right Strut Raise Solenoid Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38) and right strut down solenoid (Y39). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoids. See Electrical Component Specifications . (Group 9015-20.) Are solenoids within specification?
Result: YES:Go to Open Circuit Check. NO:Replace solenoids not within specification. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H27 GRN for continuity between pin 53 of CCU connector (X22) and pin 1 on right strut up solenoid (Y38). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair or replace circuit. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 678
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520953.06- Right Strut Raise Solenoid Current High 11
The right strut up solenoid high side driver circuit is short to ground.
Right Strut Raise Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38) and right strut down solenoid (Y39). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoids. See Electrical Component Specifications . (Group 9015-20.) Are solenoids within specification?
Result: YES:Go to Short Circuit Check. NO:Replace solenoids not within specification. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check circuit H27 GRN for ground at pin 1 of right strut up solenoid (Y38) harness connector. Is ground present?
Result: YES:Wire H27 GRN is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 53 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 679
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit H27 GRN is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 680
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520953.16- Right Strut Raise Solenoid Moderately High 11
The right strut up solenoid low side driver circuit is short to ground.
Right Strut Raise Solenoid Moderately High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Right strut up solenoid (Y38) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38). See Articulation Harness (W9) Component Location (Group 9015-10.) Check circuit R56 BLK for ground at pin 2 of right strut up solenoid (Y38) harness connector. Is ground present?
Result: YES:Wire R56 BLK is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R56 BLK for continuity between pin 12 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 681
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit R56 BLK is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 682
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520953.17- Right Strut Raise Solenoid Slightly Low 11
The right strut up solenoid low side driver circuit is open.
Right Strut Raise Solenoid Slightly Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Replace right strut up solenoid (Y38). ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R56 BLK for continuity between pin 12 of CCU connector (X22) and pin 2 on right strut up solenoid (Y38). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 683
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520953.18- Right Strut Raise Solenoid Moderately Low 11
The right strut up solenoid low side driver circuit is short to power.
Right Strut Raise Solenoid Moderately Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Right strut up solenoid (Y38) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38). See Articulation Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit R56 BLK for voltage at pin 2 of right strut up solenoid (Y38) harness connector. Is voltage present?
Result: YES:Circuit R56 BLK is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect right strut up solenoid (Y38). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R56 BLK for continuity between pin 12 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
Section 9001 page 684
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit R56 BLK is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 685
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520954.16- Right Strut Lower Solenoid Moderately High 11
The right strut down solenoid low side driver circuit is short to ground.
Right Strut Lower Solenoid Moderately High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right strut down solenoid (Y39). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Right strut down solenoid (Y39) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right strut down solenoid (Y39). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check circuit R55 BLK for ground at pin B of right strut down solenoid (Y39) harness connector. Is ground present?
Result: YES:Circuit R55 BLK is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect right strut down solenoid (Y39). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R55 BLK for continuity between pin 13 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 686
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit R55 BLK is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 687
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520954.17- Right Strut Lower Solenoid Slightly Low 11
The right strut down solenoid low side driver circuit is open.
Right Strut Lower Solenoid Slightly Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right strut down solenoid (Y39). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Right strut down solenoid (Y39) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect right strut down solenoid (Y39). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R55 BLK for continuity between pin 13 of CCU connector (X22) and pin B on right strut down solenoid (Y39). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 688
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520954.18- Right Strut Lower Solenoid Moderately Low 11
The right strut down solenoid low side driver circuit is short to power.
Right Strut Lower Solenoid Moderately Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect right strut down solenoid (Y39). See Articulation Harness (W19) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Right strut down solenoid (Y39) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect right strut down solenoid (Y39). See Articulation Harness (W19) Wiring Diagram . (Group 9015-10.) Ignition ON. Check circuit R55 BLK for voltage at pin B of right strut down solenoid (Y39) harness connector. Is voltage present?
Result: YES:Circuit R55 BLK is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect right strut down solenoid (Y39). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R55 BLK for continuity between pin 13 of CCU connector (X22) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
Section 9001 page 689
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit R55 BLK is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 690
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520957.03- Park Brake Release Valve Voltage High 11
The park brake release solenoid 2 circuit is short to power.
Park Brake Release Valve Voltage High Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Voltage Check. ( 2 ) Voltage Check
Action: →NOTE: All wiring must remain connected. Pull back protective cover to access terminal on park brake relay. Start engine. Check circuit H06 GRN for voltage at pins 1 and 2 on park brake release solenoid 2 (Y45). See Articulation Harness (W19) Component Location . (Group 9015-10.) Are 31 volts or more present?
Result: YES:Go to Short Circuit Check. NO:Program chassis control unit (CCU). ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect park brake release solenoid 2 (Y45). See Articulation Harness (W19) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit H06 GRN for voltage at pin 1 on park brake release solenoid 2 (Y45) harness connector. Is voltage present?
Result: YES:Circuit H06 GRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W19) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. <- Go to Section TOC
Section 9001 page 691
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect park brake release solenoid 2 (Y45). See Articulation Harness (W19) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 46 (circuit H06 GRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H06 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W19) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520957.05- Park Brake Release Valve Current Low 11
The park brake release solenoid 2 circuit is open.
Park Brake Release Valve Current Low Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect park brake release solenoid 2 (Y45). See Articulation Harness (W19) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 on park brake release solenoid 2 (Y45). Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Park brake release solenoid 2 (Y45) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect park brake release solenoid 2 (Y45). See Articulation Harness (W19) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 46 (circuit H06 GRN) on CCU connector (X22) and pin 1 on park brake release solenoid 2 (Y45). Check for continuity between pin 2 on park brake release solenoid 2 (Y45) and machine ground. Is continuity indicated?
Result: YES:Circuit that does not indicate continuity is open. Repair or replace circuits. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520957.06- Park Brake Release Valve Current High 11
The park brake release solenoid 2 circuit is short to ground.
Park Brake Release Valve Current High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect park brake release solenoid 2 (Y45). See Articulation Harness (W19) Component Location . (Group 9015-10.) Measure resistance between pins 1 and 2 on park brake release solenoid 2 (Y45). Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Park brake release solenoid 2 (Y45) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect park brake release solenoid 2 (Y45). See Articulation Harness (W19) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H06 GRN for ground at pin 1 on park brake release solenoid A (Y45) harness connector. Is ground present?
Result: YES:Circuit H06 GRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect park brake release solenoid 2 (Y45). See Articulation Harness (W19) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin 46 (circuit H06 GRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H06 GRN is short to circuit that indicated continuity. Repair circuits or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
520986.04- High Beam Switch Voltage Low 11
The high beam switch circuit is short to ground.
High Beam Switch Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect steering column switch (S2). See Cab Harness (W3) Component Location . (Group 9015-10.) Perform Steering Column Switch Test . (Group 9015-20.) Is continuity indicated?
Result: YES:Steering column switch (S2) malfunction. Replace switch. NO:Go to Short Circuit Check. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect steering column switch (S2). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L18 BRN for ground at pin 3 of steering column switch (S2) harness connector. Is ground present?
Result: YES:Circuit L18 BRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect steering column switch (S2). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 13 (circuit L18 BRN) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit L18 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521157.04- Hazard Lamp Enable Voltage Low 11
The hazard lamp enable circuit is short to ground.
Hazard Lamp Enable Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect 25-button sealed switch module (SSM) (OC3) (A2). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit M25 PUR for ground at pin 4 of SSM (OC3) (A2) harness connector. Is ground present?
Result: YES:Circuit M25 PUR is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect 25-button sealed switch module (SSM) (OC3) (A2). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 19 (circuit M25 PUR) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit M25 PUR is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521197.04- Exit Light Switch Voltage Low 11
The remote stairwell light switch circuit is short to ground.
Exit Light Switch Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect remote stairwell light switch (S4). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check for continuity between pin A remote stairwell light switch (S4) and machine ground. Is continuity indicated?
Result: YES:Remote stairwell light switch (S4) malfunction. Replace switch. NO:Go to Short Circuit Check. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect remote stairwell light switch (S4). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check circuit L02 BRN for ground at pin A of remote stairwell light switch (S4) harness connector. Is ground present?
Result: YES:Circuit L02 BRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect remote stairwell light switch (S4). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 52 (circuit L02 BRN) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit L02 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 700
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521350.03- Park Brake Light Circuit Voltage High 11
The service brake light switch circuit is short to power.
Park Brake Light Circuit Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect service brake light switch (B24). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit L21 BRN for voltage at pin 2 on service brake light switch (B24) connector. Is voltage present?
Result: YES:Circuit L21 BRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect service brake light switch (B24). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 23 (circuit L21 BRN) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L21 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 701
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521350.05- Park Brake Light Circuit Current Low 11
The service brake light switch circuit is open.
Park Brake Light Circuit Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect service brake light switch (B24). See Cab Harness (W3) Component Location . (Group 9015-10.) Press brake pedal. Check for continuity between terminals 2 and 3 on service brake light switch (B24). Is continuity indicated?
Result: YES:Go to Open Circuit Check. NO:Service brake light switch (B24) malfunction. Replace switch. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect service brake light switch (B24). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L21 BRN for continuity between pin 2 on service brake light switch (B24) connector and pin 23 on CCU connector (X23). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521350.06- Park Brake Light Circuit Current High 11
The service brake light switch circuit is short to ground.
Park Brake Light Circuit Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect service brake light switch (B24). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for ground at terminal 2 on service brake light switch (B24). Is ground indicated?
Result: YES:Service brake light switch (B24) malfunction. Replace switch. NO:Go to Short Circuit Check. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect service brake light switch (B24). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit L21 BRN for ground at pin 2 on service brake light switch (B24) connector. Is ground present?
Result: YES:Circuit L21 BRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect service brake light switch (B24). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 23 (circuit L21 BRN) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
Section 9001 page 703
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit L21 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 521792.03- EOL Checksum Error 11
End of line configuration error.
EOL Checksum Error Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other CAN communication diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and check. NO:Program chassis control unit (CCU). 521792.31- EOL Checksum Error 11
End of line configuration error.
EOL Checksum Error Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other CAN communication diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and check. NO:Program chassis control unit (CCU).
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Section 9001 page 704
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521834.03- Reversing Fan Mode Solenoid Voltage High 11
The left side reversing fan solenoid high side driver circuit is short to power.
Reversing Fan Mode Solenoid Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left side reversing fan solenoid (Y50). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Left side reversing fan solenoid (Y50) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left side reversing fan solenoid (Y50). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Ignition ON. Check circuit H02 GRN for voltage at pin 1 of left side reversing fan solenoid (Y50) harness connector. Is voltage present?
Result: YES:Circuit H02 GRN is short to power. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect left side reversing fan solenoid (Y50). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin K1 of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 705
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit H02 GRN is short to circuit with continuity indicated. Repair or replace circuits. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 706
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521834.05- Reversing Fan Mode Solenoid Current Low 11
The left side reversing fan solenoid high side driver circuit is open. Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.)
Reversing Fan Mode Solenoid Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left side reversing fan solenoid (Y50). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Left side reversing fan solenoid (Y50) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect left side reversing fan solenoid (Y50). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H02 GRN for continuity between pin 1 of left side reversing fan solenoid (Y50) harness connector and pin K1 of CCU connector (X21). Check circuit G57 BLK for continuity between pin 2 of left side reversing fan solenoid (Y50) harness connector and machine ground. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair or replace circuits. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
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Section 9001 page 707
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521834.06- Reversing Fan Mode Solenoid Current High 11
The left side reversing fan solenoid high side driver circuit is short to ground.
Reversing Fan Mode Solenoid Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left side reversing fan solenoid (Y50). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Left side reversing fan solenoid (Y50) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left side reversing fan solenoid (Y50). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check circuit H02 GRN for ground at pin 1 of left side reversing fan solenoid (Y50) harness connector. Is ground present?
Result: YES:Circuit H02 GRN is short to ground. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect left side reversing fan solenoid (Y50). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin K1 of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated? <- Go to Section TOC
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Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit H02 GRN is short to circuit with continuity indicated. Repair or replace circuits. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 709
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521891.01- Front Axle Oil Filter Restricted 11
The front axle oil filter is restricted.
Front Axle Oil Filter Restricted Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the front axle filter restriction switch (B67). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check for continuity between pins A and B on switch (B67). Is continuity indicated?
Result: YES:Go to Hydraulic Oil Filter Check. NO:Front axle filter restriction switch malfunction. Replace switch. ( 3 ) Hydraulic Oil Filter Check
Action: Remove front axle oil filter. See Hydraulic System Component Location . (Group 9025-15.) Is filter clogged with excessive debris?
Result: YES:Replace filter. See Replace Axle Oil Filters . (Operator′s Manual.) NO:Go to Short Circuit Check. ( 4 ) Short Circuit Check
Action: Disconnect the front axle filter restriction switch (B67). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check for ground at pin B (circuit N19 YEL) on front axle filter restriction switch (B67) connector. Is ground present?
Result: YES:Circuit N19 YEL is short to ground. Repair circuit or replace harness. NO:Go to Harness Check ( 5 ) Harness Check <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Action: Disconnect the front axle filter restriction switch (B67). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 46 (circuit N19 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit N19 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 711
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521891.03- Front Axle Oil Filter Voltage High 11
The front axle oil filter restriction switch is short to power.
Front Axle Oil Filter Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Disconnect the front axle filter restriction switch (B67). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check circuit N19 YEL for voltage at pin B on restriction switch (B67) connector. Is voltage present?
Result: YES:Circuit N19 YEL is short to power. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect front axle filter restriction switch (B67). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect CCU connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 46 (circuit N19 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit N19 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 521891.16- Front Axle Oil Filter Stuck Open 11
The front axle oil filter restriction switch is stuck open.
Front Axle Oil Filter Stuck Open Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) <- Go to Section TOC
Section 9001 page 712
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the front axle filter restriction switch (B67). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check for continuity between pins A and B on switch (B67). Is continuity indicated?
Result: YES:Problem intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Front axle filter restriction switch (B67) malfunction. Replace switch. 521922.00- Rear Brake High Temperature 11
The rear axle cooling oil temperature is very high.
Rear Brake High Temperature Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other axle cooling diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the rear axle temperature sensor (B63). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance across pins A and B on rear axle temperature sensor (B63). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
<- Go to Section TOC
Section 9001 page 713
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Diagnose high axle oil temperature. See Service Brake Overheats . (Group 9020-15.) NO:Rear axle temperature sensor (B63) malfunction. Replace sensor.
<- Go to Section TOC
Section 9001 page 714
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521922.03- Rear Brake Temperature Sensor Voltage High 11
The rear axle temperature sensor circuit is open or short to power.
Rear Brake Temperature Sensor Voltage High Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the rear axle temperature sensor (B63). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance across pins A and B on rear axle temperature sensor (B63). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Rear axle temperature sensor (B63) malfunction. Replace sensor. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect rear axle temperature sensor (B63). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit X02 YEL for continuity between pin 48 of CCU connector (X23) harness connector and pin A of rear axle temperature sensor (B63) harness connector. Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) ( 4 ) Short Circuit Check
Action: Ignition OFF. Disconnect rear axle temperature sensor (B63). See Rear Frame Harness (W12) Component Location . (Group 9015-20.) <- Go to Section TOC
Section 9001 page 715
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check X02 YEL for system voltage at pin A of sensor (B63) harness connector. Is system voltage present?
Result: YES:Circuit X02 YEL is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 5 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect rear axle temperature sensor (B63). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 48 (circuit X02 YEL) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit X02 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 716
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521922.04- Rear Brake Temperature Sensor Voltage Low 11
The rear axle temperature sensor circuit is short to ground.
Rear Brake Temperature Sensor Voltage Low Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the rear axle temperature sensor (B63). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance across pins A and B on rear axle temperature sensor (B63). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Rear axle temperature sensor (B63) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect rear axle temperature sensor (B63). See Rear Frame Harness (W12) Component Location . (Group 9015-20.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check X02 YEL for ground at pin A of sensor (B63) harness connector. Is ground present?
Result: YES:Circuit X02 YEL is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect rear axle temperature sensor (B63). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 717
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 48 (circuit X02 YEL) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit X02 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 521923.00- Mid Brake High Temperature 11
The middle axle cooling oil temperature is very high.
Mid Brake High Temperature Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other axle cooling diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the middle axle temperature sensor (B62). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance across pins A and B on middle axle temperature sensor (B62). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Diagnose high axle oil temperature. See Service Brake Overheats . (Group 9020-15.) NO:Middle axle temperature sensor (B62) malfunction. Replace sensor.
<- Go to Section TOC
Section 9001 page 718
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521923.03- Mid Brake Temperature Sensor Voltage High 11
The middle axle temperature sensor circuit is open or short to power.
Mid Brake Temperature Sensor Voltage High Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the middle axle temperature sensor (B62). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance across pins A and B on middle axle temperature sensor (B62). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Middle axle temperature sensor (B62) malfunction. Replace sensor. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect middle axle temperature sensor (B62). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit X01 YEL for continuity between pin 49 of CCU connector (X23) harness connector and pin A of middle axle temperature sensor (B62) harness connector. Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) ( 4 ) Short Circuit Check
Action: Ignition OFF. Disconnect middle axle temperature sensor (B62). See Rear Frame Harness (W12) Component Location . (Group 9015-20.) <- Go to Section TOC
Section 9001 page 719
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check X01 YEL for system voltage at pin A of sensor (B62) harness connector. Is system voltage present?
Result: YES:Circuit X01 YEL is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 5 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect middle axle temperature sensor (B62). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 49 (circuit X01 YEL) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit X01 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 720
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521923.04- Mid Brake Temperature Sensor Voltage Low 11
The middle axle temperature sensor circuit is short to ground.
Mid Brake Temperature Sensor Voltage Low Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the middle axle temperature sensor (B62). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Measure resistance across pins A and B on middle axle temperature sensor (B62). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Middle axle temperature sensor (B62) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect middle axle temperature sensor (B62). See Rear Frame Harness (W12) Component Location . (Group 9015-20.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check X01 YEL for ground at pin A of sensor (B62) harness connector. Is ground present?
Result: YES:Circuit X01 YEL is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect middle axle temperature sensor (B62). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 721
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 49 (circuit X01 YEL) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit X01 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 521924.00- Front Brake High Temperature 11
The front axle cooling oil temperature is very high.
Front Brake High Temperature Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other axle cooling diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the front axle temperature sensor (B61). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance across pins A and B on front axle temperature sensor (B61). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Diagnose high axle oil temperature. See Service Brake Overheats . (Group 9020-15.) NO:Front axle temperature sensor (B61) malfunction. Replace sensor.
<- Go to Section TOC
Section 9001 page 722
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521924.03- Front Brake Temperature Sensor Voltage High 11
The front axle temperature sensor circuit is open or short to power.
Front Brake Temperature Sensor Voltage High Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the front axle temperature sensor (B61). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance across pins A and B on front axle temperature sensor (B61). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Front axle temperature sensor (B61) malfunction. Replace sensor. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect front axle temperature sensor (B61). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit X03 YEL for continuity between pin 50 of CCU connector (X23) harness connector and pin A of front axle temperature sensor (B61) harness connector. Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 4 ) Short Circuit Check
Action: Ignition OFF. Disconnect front axle temperature sensor (B61). See Front Frame Harness (W2) Component Location . (Group 9015-20.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 723
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Ignition ON. Check X03 YEL for system voltage at pin A of sensor (B61) harness connector. Is system voltage present?
Result: YES:Circuit X03 YEL is short to power. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 5 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect front axle temperature sensor (B61). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 50 (circuit X03 YEL) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit X03 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 724
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
521924.04- Front Brake Temperature Sensor Voltage Low 11
The front axle temperature sensor circuit is short to ground.
Front Brake Temperature Sensor Voltage Low Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect the front axle temperature sensor (B61). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance across pins A and B on front axle temperature sensor (B61). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:front axle temperature sensor (B61) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect front axle temperature sensor (B61). See Front Frame Harness (W2) Component Location . (Group 9015-20.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check X03 YEL for ground at pin A of sensor (B61) harness connector. Is ground present?
Result: YES:Circuit X03 YEL is short to ground. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect front axle temperature sensor (B61). See Front Frame Harness (W2) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 725
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 50 (circuit X03 YEL) of CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit X03 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 726
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522039.03- Seat Heater Voltage High 11
The seat heater circuit is short to power.
Seat Heater Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect seat heater 2-pin connector (X65). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Seat heater OFF. Check circuit A27 ORG for voltage at pin 1 on seat heater 2-pin connector (X65). Is voltage present?
Result: YES:Circuit A27 ORG is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect seat heater 2-pin connector (X65). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 5 (circuit A27 ORG) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit A27 ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 727
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522039.05- Seat Heater Current Low 11
The seat heater circuit is open.
Seat Heater Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect seat heater 2-pin connector (X65). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pins 1 and 2 on seat heater connector (X65). Is continuity indicated?
Result: YES:Go to Open Circuit Check. NO:Seat cushion heater (R14) or back cushion heater (R15) malfunction. Replace heaters. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect seat heater 2-pin connector (X65). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A27 ORG for continuity between pin 5 on CCU connector (X23) and pin 1 on seat heater 2-pin connector (X65). Check circuit G42 BLK for continuity between pin 2 on seat heater 2-pin connector (X65) and machine ground. Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 728
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522039.06- Seat Heater Current High 11
The heat heater circuit is short to ground.
Seat Heater Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect seat heater 2-pin connector (X65). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pins 1 and 2 on seat heater connector (X65). Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Seat cushion heater (R14) or back cushion heater (R15) malfunction. Replace heaters. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect seat heater 2-pin connector (X65). See Cab Harness (W3) Component Location . (Group 9015-10.) Seat heater OFF. Check circuit A27 ORG for ground at pin 1 on seat heater 2-pin connector (X65). Is ground present?
Result: YES:Circuit A27 ORG is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect seat heater 2-pin connector (X65). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 5 (circuit A27 ORG) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
Section 9001 page 729
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit A27 ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 730
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522176.01- Secondary Steering Pressure Very Low 11
The secondary steering pressure sensor low side driver circuit is short to ground.
Secondary Steering Pressure Very Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other secondary steering diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and check. NO:Go to Component Check. ( 3 ) Component Check
Action: Ignition OFF. Disconnect secondary steering pressure sensor (B13). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Test sensor (B13). See Hydraulic Pressure Sensors Test . (Group 9015-20.) Compare to specification. See Electrical Component Specifications . (Group 9015-20.) Is sensor within specification?
Result: YES:Go to Short Circuit Check. NO:Secondary steering pressure sensor malfunction. Replace sensor. ( 4 ) Short Circuit Check
Action: Disconnect secondary steering pressure sensor (B13). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 49 (circuit R37 BLK) and machine ground. Is continuity indicated?
<- Go to Section TOC
Section 9001 page 731
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit R37 BLK is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 732
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522176.03- Secondary Steering Pressure Sensor Voltage High 11
The secondary steering pressure is low with engine running.
Secondary Steering Pressure Sensor Voltage High Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect secondary steering pressure sensor (B13). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Test sensor (B13). See Hydraulic Pressure Sensors Test . (Group 9015-20.) Compare to specification. See Electrical Component Specifications . (Group 9015-20.) Is sensor within specification?
Result: YES:Go to Short Circuit Check. NO:Secondary steering pressure sensor (B13) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect secondary steering pressure sensor (B13). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit M17 PUR for voltage at pin C of secondary steering pressure sensor (B13) harness connector. Is voltage present?
Result: YES:Circuit M17 PUR is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 4 ) Open Circuit Check
Action: Turn battery disconnect switch OFF. Disconnect secondary steering pressure sensor (B13). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 733
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin 38 (circuit M17 PUR) on CCU connector (X22) and pin C on secondary steering pressure sensor (B13). Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) ( 5 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect secondary steering pressure sensor (B13). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 38 (circuit M17 PUR) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit M17 PUR is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 734
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522176.04- Secondary Steering Pressure Sensor Voltage Low 11
The secondary steering pressure sensor circuit is short to ground.
Secondary Steering Pressure Sensor Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect secondary steering pressure sensor (B13). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Test sensor (B13). See Hydraulic Pressure Sensors Test . (Group 9015-20.) Compare to specification. See Electrical Component Specifications . (Group 9015-20.) Is sensor within specification?
Result: YES:Go to Short Circuit Check. NO:Secondary steering pressure sensor (B13) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect secondary steering pressure sensor (B13). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Check circuit M17 PUR for ground at pin C of secondary steering pressure sensor (B13) harness connector. Is ground present?
Result: YES:Circuit M17 PUR is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect secondary steering pressure sensor (B13). See Hydraulic Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 38 (circuit M17 PUR) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 735
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit M17 PUR is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Hydraulic Harness (W9) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 736
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522279.03- Brake Control Valve 2 Voltage High 11
The electric brake valve solenoid high side driver circuit is short to power.
Brake Control Valve 2 Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit H15 GRN for voltage at pin 1 of electric brake valve solenoid (Y8) harness connector. Is voltage present?
Result: YES:Circuit H15 GRN is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin C1 of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit H15 GRN is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 737
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522279.05- Brake Control Valve 2 Current Low 11
The electric brake valve solenoid high side driver circuit is open.
Brake Control Valve 2 Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Electric brake valve solenoid (Y8) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit H15 GRN for continuity between pin 1 of electric brake valve solenoid (Y8) harness connector and pin C1 of CCU connector (X21). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 738
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522279.06- Brake Control Valve 2 Current High 11
The electric brake valve solenoid high side driver circuit is short to ground.
Brake Control Valve 2 Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Electric brake valve solenoid (Y8) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check circuit H15 GRN for ground at pin 1 of electric brake valve solenoid (Y8) harness connector. Is ground present?
Result: YES:Circuit H15 GRN is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin C1 of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated? <- Go to Section TOC
Section 9001 page 739
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit H15 GRN is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 740
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522279.16- Brake Control Valve 2 Moderately High 11
The electric brake valve solenoid low side driver circuit is short to ground.
Brake Control Valve 2 Moderately High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Electric brake valve solenoid (Y8) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check circuit R64 BLK for ground at pin 2 of electric brake valve solenoid (Y8) harness connector. Is ground present?
Result: YES:Circuit R64 BLK is short to ground. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin G2 of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated? <- Go to Section TOC
Section 9001 page 741
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit R64 BLK is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 742
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522279.17- Brake Control Valve 2 Slightly Low 11
The electric brake valve solenoid low side driver circuit is open.
Brake Control Valve 2 Slightly Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Open Circuit Check. NO:Electric brake valve solenoid (Y8) malfunction. Replace solenoid. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit R64 BLK for continuity between pin 2 of electric brake valve solenoid (Y8) harness connector and pin G2 of CCU connector (X21). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 743
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522279.18- Brake Control Valve 2 Moderately Low 11
The electric brake valve solenoid low side driver circuit is short to power.
Brake Control Valve 2 Moderately Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9025-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Check solenoid. See Electrical Component Specifications . (Group 9015-20.) Is solenoid within specification?
Result: YES:Go to Short Circuit Check. NO:Electric brake valve solenoid (Y8) malfunction. Replace solenoid. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Ignition ON. Check circuit R64 BLK for voltage at pin 2 of electric brake valve solenoid (Y8) harness connector. Is voltage present?
Result: YES:Circuit R64 BLK is short to power. Repair circuit or replace harness. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Ignition OFF. Disconnect electric brake valve solenoid (Y8). See Articulation Harness (W9) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin G2 of CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 744
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit R64 BLK is short to circuit with continuity indicated. Repair or replace circuits. see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 745
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522312.05- Windshield Washer Pump Current Low 11
The front windshield washer pump motor circuit is open.
Windshield Washer Pump Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect front windshield washer pump motor (M5). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Apply 24 volts to terminal 1 and ground to terminal 2 on motor (M5). Does front windshield washer pump motor run?
Result: YES:Go to Open Circuit Check. NO:Front windshield washer pump motor (M5) malfunction. Replace motor. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect front windshield washer pump motor (M5). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A04 ORG for continuity between pin 1 on motor (M5) harness connector and pin G4 on chassis control unit (CCU) connector (X21). Check circuit G27 BLK for continuity between pin 2 on motor (M5) harness connector and machine ground. Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.)
<- Go to Section TOC
Section 9001 page 746
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522312.06- Windshield Washer Pump Current High 11
The front windshield washer pump motor high side driver circuit is short to ground.
Windshield Washer Pump Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect front windshield washer pump motor (M5). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Apply 24 volts to terminal 1 and ground to terminal 2 on motor (M5). Does front windshield washer pump motor run?
Result: YES:Go to Short Circuit Check. NO:Front windshield washer pump motor (M5) malfunction. Replace motor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect front windshield washer pump motor (M5). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check circuit A04 ORG for ground at pin 1 on motor (M5) harness connector. Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect front windshield washer pump motor (M5). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin G4 (circuit A04 ORG) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated? <- Go to Section TOC
Section 9001 page 747
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit A04 ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 748
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522312.16- Windshield Washer Pump Moderately High 11
The front windshield washer pump motor high side driver circuit is short to ground.
Windshield Washer Pump Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect front windshield washer pump motor (M5). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Apply 24 volts to terminal 1 and ground to terminal 2 on motor (M5). Does front windshield washer pump motor run?
Result: YES:Go to Short Circuit Check. NO:Front windshield washer pump motor (M5) malfunction. Replace motor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect front windshield washer pump motor (M5). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check circuit A04 ORG for ground at pin 1 on motor (M5) harness connector. Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect front windshield washer pump motor (M5). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin G4 (circuit A04 ORG) on CCU connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated? <- Go to Section TOC
Section 9001 page 749
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit A04 ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 750
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522405.03- Park Brake Pressure Switch Voltage High 11
The park brake pressure switch is short to power.
Park Brake Pressure Switch Voltage High Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect park brake pressure switch (B15). See Articulation Harness (W11) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit N09 YEL for voltage at pin 1 on park brake pressure switch (B15) harness connector. Is voltage present?
Result: YES:Circuit N09 YEL is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect park brake pressure switch (B15). See Articulation Harness (W11) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 24 (circuit N09 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit N09 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 751
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522405.04- Park Brake Pressure Switch Voltage Low 11
The park brake pressure switch is short to ground.
Park Brake Pressure Switch Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect park brake pressure switch (B15). See Articulation Harness (W11) Component Location . (Group 9015-10.) Check for continuity between terminals 1 and 2 on park brake pressure switch (B15). Is continuity indicated?
Result: YES:Park brake pressure switch (B15) malfunction. Replace switch. NO:Go to Short Circuit Check. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect park brake pressure switch (B15). See Articulation Harness (W11) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit N09 YEL for ground at pin 1 on park brake pressure switch (B15) harness connector. Is ground present?
Result: YES:Circuit N09 YEL is short to ground. Repair circuit or replace harness. See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect park brake pressure switch (B15). See Articulation Harness (W11) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 24 (circuit N09 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, <- Go to Section TOC
Section 9001 page 752
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
and X23). Is continuity indicated?
Result: YES:Circuit N09 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Articulation Harness (W11) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 753
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522427.10- Front Wiper Park Signal Invalid 11
The chassis control unit (CCU) has lost the front windshield wiper motor park signal.
Front Wiper Park Signal Invalid Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Verify that the front wiper is not stuck or the movement is hindered from proper operation. Are wipers stuck or hindered in any way?
Result: YES:Remove obstruction or repair wiper to restore proper operation. NO:Go to Fuse Check. ( 3 ) Fuse Check
Action: Ignition OFF. Remove fuse (F18). See Fuse and Relay Specifications . (Group 9015-10.) Check fuse (F18) for continuity. Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Replace fuse without continuity indicated. ( 4 ) Short Circuit Check
Action: Ignition OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check circuit G38 BLK for voltage at pin 6 on front wiper motor connector. Check circuit A20 ORG for voltage at pin 1 on front wiper motor connector. Is voltage present?
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit with voltage is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 5 ) Open Circuit Check
Action: Ignition OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit connector (CCU) (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit G38 BLK for continuity between pin 6 on front wiper motor connector and frame ground. Check circuit A20 ORG for continuity between pin 1 on front wiper motor connector and pin 28 on (CCU) connector (X23). Is continuity indicated?
Result: YES:Checks complete. NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 6 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 28 (circuit A20 ORG) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit A20 ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 755
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522434.05- Front Wiper Lo Speed Motor Current Low 11
The front windshield wiper motor low speed circuit is open.
Front Wiper Lo Speed Motor Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 24 volts to pin 4 on motor (M3). Does motor operate?
Result: YES:Go to Open Circuit Check. NO:Front windshield wiper motor malfunction. Replace motor. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A18 ORG for continuity between pin 4 on front wiper motor (M3) harness connector and pin 4 on CCU connector (X22). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
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Section 9001 page 756
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522434.06- Front Wiper Lo Speed Motor Current High 11
The front windshield wiper motor low speed circuit is short to ground.
Front Wiper Lo Speed Motor Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 24 volts to pin 4 on motor (M3). Does motor operate?
Result: YES:Go to Short Circuit Check. NO:Front windshield wiper motor malfunction. Replace motor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A18 ORG for ground at pin 4 on front wiper motor (M3) harness connector. Is ground present?
Result: YES:Circuit A18 ORG is short to ground. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 4 (circuit A18 ORG) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated? <- Go to Section TOC
Section 9001 page 757
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit A18 ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 758
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522434.16- Front Wiper Lo Speed Motor Current Moderately High 11
The front windshield wiper motor low speed circuit is short to power.
Front Wiper Lo Speed Motor Current Moderately High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 24 volts to pin 4 on front wiper motor (M3). Does motor operate?
Result: YES:Go to Short Circuit Check. NO:Front windshield wiper motor malfunction. Replace motor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A18 ORG for voltage at pin 4 on motor (M3) harness connector. Is voltage present?
Result: YES:Circuit A18 ORG is short to power. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 4 (circuit A18 ORG) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 759
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit A18 ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 760
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522435.05- Front Wiper High Speed Motor Current Low 11
The front windshield wiper motor high speed circuit is open.
Front Wiper High Speed Motor Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 24 volts to pin 2 on motor (M3). Does motor operate?
Result: YES:Go to Open Circuit Check. NO:Front windshield wiper motor malfunction. Replace motor. ( 3 ) Open Circuit Check
Action: Ignition OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X22). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A19 ORG for continuity between pin 2 on front windshield wiper motor (M3) harness connector and pin 30 on CCU connector (X22). Is continuity indicated?
Result: YES:Program chassis control unit (CCU). NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.)
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Section 9001 page 761
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522435.06- Front Wiper High Speed Motor Current High 11
The front windshield wiper motor high speed circuit is short to ground.
Front Wiper High Speed Motor Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 24 volts to pin 2 on motor (M3). Does motor operate?
Result: YES:Go to Short Circuit Check. NO:Front windshield wiper motor malfunction. Replace motor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A19 ORG for ground at pin 2 on motor (M3) harness connector. Is ground present?
Result: YES:Circuit A19 ORG is short to ground. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 30 (circuit A19 ORG) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated? <- Go to Section TOC
Section 9001 page 762
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit A19 ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 763
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
522435.16- Front Wiper High Speed Motor Current Moderately High 11
The front windshield wiper motor high speed circuit is short to power.
Front Wiper High Speed Motor Current Moderately High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 24 volts to pin 2 on motor (M3). Does motor operate?
Result: YES:Go to Short Circuit Check. NO:Front windshield wiper motor. Replace motor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit A19 ORG for voltage at pin 2 on motor (M3) harness connector. Is voltage present?
Result: YES:Circuit A19 ORG is short to power. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect front windshield wiper motor (M3). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 30 (circuit A19 ORG) on CCU connector (X22) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 764
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit A19 ORG is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 522517.31- TC Stall Protection Very High 11
Transmission stall has been active for more than 30 seconds.
TC Stall Protection Very High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Ignition ON. Clear codes from the chassis control unit (CCU). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Check for active DTCs. Is DTC 522517.31 still active?
Result: YES:Program chassis control unit (CCU). NO:Checks complete.
<- Go to Section TOC
Section 9001 page 765
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
523217.04- VP3 Supply Voltage Low 11
VP3 supply voltage is short to ground.
VP3 Supply Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Fuse Check. ( 2 ) Fuse Check
Action: Ignition OFF. Remove fuse (F7). See Fuse and Relay Specifications . (Group 9015-10.) Check fuse (F7) for continuity. Is continuity indicated?
Result: YES:Go to Short Circuit Check. NO:Replace fuse without continuity indicated. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect chassis control unit connector (CCU) (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit P61 RED for ground at pin 2 on CCU harness connector (X23). Is ground present?
Result: YES:Go to Harness Check. NO:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit P61 RED for continuity between pin 2 on chassis control unit (CCU) connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated? <- Go to Section TOC
Section 9001 page 766
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Result: YES:Circuit P61 RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 523218.03- VP2 Supply Voltage High 11
VP2 supply circuit is overvoltage.
VP2 Supply Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Ignition ON. Clear codes from the chassis control unit (CCU). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Check for active DTCs. Is DTC 523218.03 still active?
Result: YES:Program chassis control unit (CCU). NO:Checks complete.
<- Go to Section TOC
Section 9001 page 767
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
523218.04- VP2 Supply Voltage Low 11
VP2 supply circuit is short to ground.
VP2 Supply Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect chassis control unit connector (CCU) (X21). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit P60 RED for ground at pin L1 on CCU harness connector (X21). Is ground present?
Result: YES:Go to Harness Check. NO:Circuit P60 RED is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit P60 RED for continuity between pin L1 on chassis control unit (CCU) connector (X21) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit P60 RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 523219.03- VP1 Supply Voltage High 11
VP1 supply circuit is overvoltage.
VP1 Supply Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: <- Go to Section TOC
Section 9001 page 768
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Ignition ON. Clear codes from the chassis control unit (CCU). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Check for active DTCs. Is DTC 523219.03 still active?
Result: YES:Program chassis control unit (CCU). NO:Checks complete.
<- Go to Section TOC
Section 9001 page 769
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
523219.04- VP1 Supply Voltage Low 11
VP1 is short to ground.
VP1 Supply Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect chassis control unit (CCU) connector (X24). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit B10 RED for ground at pin 1 on CCU connector (X24). Is ground present?
Result: YES:Circuit B10 Red is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit B10 RED for continuity between chassis control unit (CCU) connector (X24) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit B10 RED is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
<- Go to Section TOC
Section 9001 page 770
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
523489.03- Service Lights Voltage High 11
The service light circuit is short to power.
Service Lights Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect service light (E21). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Ignition ON. Service light OFF. Check circuit L07 BRN for voltage at pin 1 on service light (E21) connector. Is voltage present?
Result: YES:Circuit L07 BRN is short to power. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect service light (E21). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit L07 BRN) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L07 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
523489.05- Service Lights Current Low 11
The service light circuit is open.
Service Lights Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect service light (E21). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Apply 24 volts to pin 1 and ground to pin 2 on service light (E21). Does service light (E21) illuminate?
Result: YES:Go to Harness Check. NO:Service light (E21) malfunction. Replace service light. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect service light (E21). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit L07 BRN) on CCU connector (X23) and pin 1 on service light (E21). Check for continuity between pin 2 (circuit G31 BLK) on service light (E21) connector and machine ground. Is continuity indicated?
Result: YES:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 772
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
523489.06- Service Lights Current High 11
The service light circuit is short to ground.
Service Lights Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect service light (E21). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Apply 24 volts to pin 1 on service light (E21) and ground to pin 2. Does service light (E21) illuminate?
Result: YES:Go to Short Circuit Check. NO:Service light (E21) malfunction. Replace service light. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect service light (E21). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check circuit L07 BRN for ground at pin 1 on service light (E21) connector. Is ground present?
Result: YES:Circuit L07 BRN is short to ground. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect service light (E21). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 1 (circuit L07 BRN) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit L07 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 523702.09- Flexpower Data Bad Update Rate 11
Engine flexpower data was not received by the chassis control unit.
Flexpower Data Bad Update Rate Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to CAN Circuit Check. ( 2 ) CAN Circuit Check
Action: Ignition OFF. Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Repair CAN circuit. 523702.31- Flexpower No Information 11
Flexpower no information.
Flexpower No Information Diagnostic Procedure Alarm Level: Caution Indicator (yellow) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are other CAN communication diagnostic trouble codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. <- Go to Section TOC
Section 9001 page 774
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
NO:Go to CAN Circuit Check. ( 2 ) CAN Circuit Check
Action: Ignition OFF. Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Repair CAN circuit.
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Section 9001 page 775
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
523757.03- Operator Exit Light Voltage High 11
The left stairwell light high side driver circuit is short to power.
Operator Exit Light Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Ignition OFF. Disconnect left stairwell light (E19). See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Stairwell light OFF. Check circuit L25 BRN for voltage at pin 1 on left stairwell light (E19) connector. Is voltage present?
Result: YES:Circuit L25 BRN is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect left stairwell light (E19). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 30 (circuit L25 BRN) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit L25 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 776
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
523757.05- Operator Exit Light Current Low 11
The left stairwell light high side driver circuit is open.
Operator Exit Light Current Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left stairwell light (E19). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 24 volts to pin 1 and ground to pin 2 on left stairwell light (E19). Does light (E19) illuminate?
Result: YES:Go to Harness Check. NO:Left stairwell light (E19) malfunction. Replace light. ( 3 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect left stairwell light (E19). See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 30 (circuit L25 BRN) on CCU connector (X23) and pin 1 on left stairwell light (E14). Check for continuity between pin 2 (circuit G48 BLK) on left stairwell light (E19) and machine ground. Is continuity indicated?
Result: YES:Circuit that does not indicate continuity is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 777
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
523757.06- Operator Exit Light Current High 11
The left stairwell light high side driver circuit is short to ground.
Operator Exit Light Current High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect left stairwell light (E19). See Cab Harness (W3) Component Location . (Group 9015-10.) Apply 24 volts to pin 1 and ground to pin 2 on left stairwell light (E19) . Does light (E19) illuminate?
Result: YES:Go to Short Circuit Check. NO:Left stairwell light (E19) malfunction. Replace light. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect left stairwell light (E19). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit L25 BRN for ground at pin 1 on left stairwell light (E19) connector. Is ground present?
Result: YES:Circuit L25 BRN is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect left stairwell light (E19). See Cab Harness (W3) Component Location . (Group 9015-10.)) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 30 (circuit L25 BRN) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). <- Go to Section TOC
Section 9001 page 778
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Is continuity indicated?
Result: YES:Circuit L25 BRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 524067.01- Rear Axle Lube Pressure Very Low 11
The rear axle lube oil pressure is low.
Rear Axle Lube Pressure Very Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Rear Axle Lube Pressure Check. ( 2 ) Rear Axle Lube Pressure Check
Action: Ignition OFF. Is rear axle lube pressure to specification?
Result: YES:Go to Rear Axle Pressure Sensor Check. NO:Check for kinked or restricted hydraulic lines. Check cooler for restrictions. Replace pump if necessary. ( 3 ) Rear Axle Pressure Sensor Check
Action: Ignition OFF. Disconnect rear axle pressure sensor (B55). ˋ See Rear Frame Harness (W20) Component Location. (Group 9015-10.) Test rear axle pressure sensor (B55). See Hydraulic Pressure Sensors Test . (Group 9015-20.) Compare to specification. See Electrical Component Specifications . (Group 9015-20.) Is sensor within specification?
Result: YES:Diagnose rear axle pressure malfunction. See TEAMMATE™ V 1500 Series Axle 370E, 410E, 460E Series Outboard Planetary Axles . (CTM115319.) NO:Rear axle pressure sensor (B55) malfunction. Replace sensor.
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Section 9001 page 779
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
524067.03- Rear Axle Lube Pressure Sensor Voltage High 11
The rear axle pressure sensor circuit is open or short to power.
Rear Axle Lube Pressure Sensor Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect rear axle pressure sensor (B55). See Rear Frame Harness (W20) Component Location. (Group 9015-10.) Test pressure sensor (B55). See Hydraulic Pressure Sensors Test . (Group 9015-20.) Compare to specification. See Electrical Component Specifications . (Group 9015-20.) Is sensor within specification?
Result: YES:Go to Short Circuit Check. NO:Rear axle pressure sensor (B55) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect rear axle pressure sensor (B55). See Rear Frame Harness (W20) Component Location. (Group 9015-10.) Ignition ON. Check circuit N05 YEL for voltage at pin C on rear axle pressure sensor (B55) harness. Is voltage present?
Result: YES:Circuit N05 YEL is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W20) Component Location. (Group 9015-10.) NO:Go to Open Circuit Check. ( 4 ) Open Circuit Check
Action: Ignition OFF. Disconnect rear axle pressure sensor (B55). See Rear Frame Harness (W20) Component Location. (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 780
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check circuit N05 YEL for continuity between pin C on rear axle pressure sensor (B55) harness and pin 45 on (CCU) connector (X23). Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W20) Component Location. (Group 9015-10.) ( 5 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect rear axle pressure sensor (B55). See Rear Frame Harness (W20) Component Location. (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 45 (circuit N05 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit N05 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W20) Component Location. (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 781
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
524067.04- Rear Axle Lube Pressure Sensor Voltage Low 11
The rear axle pressure sensor circuit is short to ground.
Rear Axle Lube Pressure Sensor Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect rear axle pressure sensor (B55). See Rear Frame Harness (W20) Component Location. (Group 9015-10.) Test pressure sensor (B55). See Hydraulic Pressure Sensors Test . (Group 9015-20.) Compare to specification. See Electrical Component Specifications . (Group 9015-20.) Is sensor within specification?
Result: YES:Go to Short Circuit Check. NO:Rear axle pressure sensor (B55) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect rear axle pressure sensor (B55). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Ignition ON. Check circuit N05 YEL for ground at pin C on rear axle pressure sensor (B55) harness. Is ground present?
Result: YES:Circuit N05 YEL is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W20) Component Location. (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect rear axle pressure sensor (B55). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group <- Go to Section TOC
Section 9001 page 782
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
9015-10.) Check for continuity between pin 45 (circuit N05 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit N05 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W20) Component Location. (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 783
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
524068.01- Front Axle Lube Pressure Very Low 11
The front axle lube oil pressure is low.
Front Axle Lube Pressure Very Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Front Axle Lube Pressure Check. ( 2 ) Front Axle Lube Pressure Check
Action: Ignition OFF. Perform Axle Cooling Pump Pressure Test and Flow Test . (Group 9020-25.) Is front axle lube pressure to specification?
Result: YES:Go to Front Axle Pressure Sensor Check. NO:Check for kinked or restricted hydraulic lines.Check differential gear case oil suction screen for debris. See Differential Gear Case Assembly — Assembly . (CTM115319.) Check cooler for restrictions.Replace pump if necessary. ( 3 ) Front Axle Pressure Sensor Check
Action: Ignition OFF. Disconnect front axle pressure sensor (B64). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Test pressure sensor (B64). See Hydraulic Pressure Sensors Test . (Group 9015-20.) Compare to specification. See Electrical Component Specifications . (Group 9015-20.) Is sensor within specification?
Result: YES:Diagnose front axle pressure malfunction. See TEAMMATE™ V 1500 Series Axle 370E, 410E, 460E Series Outboard Planetary Axles . (CTM115319.) NO:Front axle pressure sensor (B64) malfunction. Replace sensor.
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Section 9001 page 784
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
524068.03- Front Axle Lube Pressure Sensor Voltage High 11
The front axle pressure sensor circuit is open or short to power.
Front Axle Lube Pressure Sensor Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect front axle pressure sensor (B64). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Test pressure sensor (B64). See Hydraulic Pressure Sensors Test . (Group 9015-20.) Compare to specification. See Electrical Component Specifications . (Group 9015-20.) Is sensor within specification?
Result: YES:Go to Short Circuit Check. NO:Front axle pressure sensor (B64) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect front axle pressure sensor (B64). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Ignition ON. Check circuit N11 YEL for voltage at pin C on front axle pressure sensor (B64) harness. Is voltage present?
Result: YES:Circuit N11 YEL is short to power. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 4 ) Open Circuit Check
Action: Ignition OFF. Disconnect front axle pressure sensor (B64). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 785
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check circuit N11 YEL for continuity between pin C on front axle pressure sensor (B64) harness and pin 47 on (CCU) connector (X23). Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 5 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect front axle pressure sensor (B64). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 47 (circuit N11 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit N11 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 786
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
524068.04- Front Axle Lube Pressure Sensor Voltage Low 11
The front axle pressure sensor circuit is short to ground.
Front Axle Lube Pressure Sensor Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect front axle pressure sensor (B64). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Test pressure sensor (B64). See Hydraulic Pressure Sensors Test . (Group 9015-20.) Compare to specification. See Electrical Component Specifications . (Group 9015-20.) Is sensor within specification?
Result: YES:Go to Short Circuit Check. NO:Front axle pressure sensor (B64) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect front axle pressure sensor (B64). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Ignition ON. Check circuit N11 YEL for ground at pin C on front axle pressure sensor (B64) harness. Is ground present?
Result: YES:Circuit N11 YEL is short to ground. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect front axle pressure sensor (B64). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
Section 9001 page 787
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check for continuity between pin 47 (circuit N11 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit N11 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Front Frame Harness (W2) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) NO:Program chassis control unit (CCU). 524069.01- M Axle Lube Pressure Very Low 11
The middle axle lube oil pressure is low.
M Axle Lube Pressure Very Low Diagnostic Procedure Alarm Level: Stop Indicator (red) Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Middle Axle Lube Pressure Check
Action: Ignition OFF. Perform Axle Cooling Pump Pressure Test and Flow Test . (Group 9020-25.) Is middle axle lube pressure to specification?
Result: YES:Go to Middle Axle Pressure Sensor Check. NO:Check for kinked or restricted hydraulic lines. Check cooler for restrictions. Replace pump if necessary. ( 2 ) Middle Axle Pressure Sensor Check
Action: Ignition OFF. Disconnect middle axle pressure sensor (B65). See Rear Frame Harness (W20) Component Location. (Group 9015-10.) Test pressure sensor (B65). See Hydraulic Pressure Sensors Test . (Group 9015-20.) Compare to specification. See Electrical Component Specifications . (Group 9015-20.) Is sensor within specification?
Result: YES:Diagnose middle axle pressure malfunction. See TEAMMATE™ V 1500 Series Axle 370E, 410E, 460E Series Outboard Planetary Axles . (CTM115319.) NO:Middle axle pressure sensor (B65) malfunction. Replace sensor.
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
524069.03- M Axle Lube Pressure Sensor Voltage High 11
The middle axle pressure sensor circuit is open or short to power.
M Axle Lube Pressure Sensor Voltage High Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect middle axle pressure sensor (B65). See Rear Frame Harness (W20) Component Location. (Group 9015-10.) Test pressure sensor (B65). See Hydraulic Pressure Sensors Test . (Group 9015-20.) Compare to specification. See Electrical Component Specifications . (Group 9015-20.) Is sensor within specification?
Result: YES:Go to Short Circuit Check. NO:Middle axle pressure sensor (B65) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect middle axle pressure sensor (B65). See Rear Frame Harness (W20) Component Location. (Group 9015-10.) Ignition ON. Check circuit N03 YEL for voltage at pin C on middle axle pressure sensor (B65) harness. Is voltage present?
Result: YES:Circuit N03 YEL is short to power. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W12) Wiring Diagram . (Group 9015-10.) NO:Go to Open Circuit Check. ( 4 ) Open Circuit Check
Action: Ignition OFF. Disconnect middle axle pressure sensor (B65). See Rear Frame Harness (W20) Component Location. (Group 9015-10.) Disconnect chassis control unit (CCU) connector (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
Check circuit N03 YEL for continuity between pin C on middle axle pressure sensor (B65) harness and pin 22 on (CCU) connector (X23). Is continuity indicated?
Result: YES:Go to Harness Check. NO:Circuit that does not indicate continuity is open. Repair or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W20) Component Location. (Group 9015-10.) ( 5 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect middle axle pressure sensor (B65). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 22 (circuit N03 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit N03 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W20) Component Location. (Group 9015-10.) NO:Program chassis control unit (CCU).
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Section 9001 page 790
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 30: Chassis Control Unit (CCU) Diagnostic Trouble Codes
524069.04- M Axle Lube Pressure Sensor Voltage Low 11
The middle axle pressure sensor circuit is short to ground.
M Axle Lube Pressure Sensor Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Indicator Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Component Check
Action: Ignition OFF. Disconnect middle axle pressure sensor (B65). See Rear Frame Harness (W20) Component Location. (Group 9015-10.) Test pressure sensor (B65). See Hydraulic Pressure Sensors Test . (Group 9015-20.) Compare to specification. See Electrical Component Specifications . (Group 9015-20.) Is sensor within specification?
Result: YES:Go to Short Circuit Check. NO:Middle axle pressure sensor (B65) malfunction. Replace sensor. ( 3 ) Short Circuit Check
Action: Ignition OFF. Disconnect middle axle pressure sensor (B65). See Rear Frame Harness (W20) Component Location. (Group 9015-10.) Ignition ON. Check circuit N03 YEL for ground at pin C on middle axle pressure sensor (B65) harness. Is ground present?
Result: YES:Circuit N03 YEL is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W20) Component Location. (Group 9015-10.) NO:Go to Harness Check. ( 4 ) Harness Check
Action: Turn battery disconnect switch OFF. Disconnect middle axle pressure sensor (B65). See Rear Frame Harness (W20) Component Location. (Group 9015-10.) Disconnect chassis control unit (CCU) connectors (X21, X22, and X23). See Cab Harness (W3) Component Location . (Group <- Go to Section TOC
Section 9001 page 791
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Section 9001 - DIAGNOSTICS
Group 40: CAN Monitor Unit (CMU) Diagnostic Trouble Codes
9015-10.) Check for continuity between pin 22 (circuit N03 YEL) on CCU connector (X23) and all other pins on CCU connectors (X21, X22, and X23). Is continuity indicated?
Result: YES:Circuit N03 YEL is short to circuit that indicated continuity. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) See Rear Frame Harness (W20) Component Location. (Group 9015-10.) NO:Program chassis control unit (CCU). 702141.11- Transmission Movement in Neutral 11
The transmission output shaft speed is greater than 250 rpm when machine is in neutral.
Transmission Movement in Neutral Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) →NOTE: It is possible to generate this code if there is machine movement with no park brake engagement. If possible, verify that the machine was in park when this code was generated. ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Component Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check diagnostic trouble codes. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are there any parking brake codes present?
Result: YES:Correct other diagnostic trouble codes and recheck. NO:Go to Park Brake Operation Check. ( 3 ) Park Brake Operation Check
Action: Check park brake operation. See Operational Checkout . (Group 9005-10.) Does the park brake function properly?
Result: YES:Program chassis control unit. NO: See Park Brake Will Not Hold . (Group 9020-15.) <- Go to Section TOC
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Section 9001 - DIAGNOSTICS
<- Go to Section TOC
Group 40: CAN Monitor Unit (CMU) Diagnostic Trouble Codes
Section 9001 page 793
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 40: CAN Monitor Unit (CMU) Diagnostic Trouble Codes
Group 40 - CAN Monitor Unit (CMU) Diagnostic Trouble Codes 002000.09- ECU CAN Comm Bad Update Rate 215
Controller area network (CAN) communication error; the CAN monitor unit (CMU) lost communication with the engine control unit (ECU).
ECU CAN Comm Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, See CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-10.) ( 1 ) Controller Sensors Check
Action: Connect Service ADVISOR ™ . See Service ADVISOR™ Connection Procedure . (Group 9015-20.) View ECU input sensor data on Service ADVISOR™. Are all ECU sensor values displayed?
Result: YES:Program CAN monitor unit (CMU). NO:Go to Fuse Check. ( 2 ) Fuse Check
Action: Ignition OFF. Remove fuses (F14 and F28). See Fuse and Relay Specifications . (Group 9015-10.) Check fuses (F14 and F28) for continuity. Is continuity indicated?
Result: YES:Go to Voltage Check. NO:Replace fuse(s) without continuity indicated. ( 3 ) Voltage Check
Action: Ignition OFF. Disconnect ECU connector (X13). See Engine Harness (W17) Component Location . (Group 9015-10.) Ignition ON. Check for voltage at the following pins on ECU connector (X13): 7—wire P24 RED 13—wire P09 RED 14—wire P09 RED 23—wire P09 RED 24—wire P09 RED Is voltage indicated?
Result: YES:Go to Ground Circuit Check. <- Go to Section TOC
Section 9001 page 794
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Section 9001 - DIAGNOSTICS
Group 40: CAN Monitor Unit (CMU) Diagnostic Trouble Codes
NO:Circuit(s) without voltage is open. Repair circuit or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) ( 4 ) Ground Circuit Check
Action: Ignition OFF. Disconnect ECU connector (X13). See Engine Harness (W17) Component Location . (Group 9015-10.) Check for ground at the following pins on ECU connector (X13): 27—G17 BLK 43—G17 BLK 44—G17 BLK Is ground present?
Result: YES:Go to CAN Circuit Check. NO:Circuit G17 BLK is open. Repair circuit or replace harness. See Engine Harness (W17) Wiring Diagram . (Group 9015-10.) ( 5 ) CAN Circuit Check
Action: Ignition OFF. Test CAN circuit. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Program engine control unit (ECU). NO:Repair CAN circuit.
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Section 9001 page 795
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 40: CAN Monitor Unit (CMU) Diagnostic Trouble Codes
002003.09- TCU CAN Comm Bad Update Rate 215
Controller area network (CAN) communication error; the CAN monitor unit (CMU) lost communication with the transmission control unit (TCU).
TCU CAN Comm Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, See CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-10.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Controller Sensors Check. ( 2 ) Controller Sensors Check
Action: Connect Service ADVISOR ™ . See Service ADVISOR™ Connection Procedure . (Group 9015-20.) View TCU input sensor data on Service ADVISOR™. Are all TCU sensor values displayed?
Result: YES:Program CAN monitor unit (CMU). NO:Go to Fuse Check. ( 3 ) Fuse Check
Action: Ignition OFF. Disconnect fuses (F11 and F25). See Fuse and Relay Specifications . (Group 9015-10.) Check fuses (F11 and F25) for continuity. Is continuity indicated?
Result: YES:Go to Voltage Check. NO:Replace fuse(s) without continuity indicated. ( 4 ) Voltage Check
Action: Ignition OFF. Disconnect transmission control unit (TCU) connector. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Ignition ON. Check circuit P35 RED for voltage at pin 8 on TCU connector. Check circuit P37 RED for voltage at pins 2 and 5 on TCU connector. <- Go to Section TOC
Section 9001 page 796
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Section 9001 - DIAGNOSTICS
Group 40: CAN Monitor Unit (CMU) Diagnostic Trouble Codes
Is system voltage (approximately 24 volts) present at all pins?
Result: YES:Go to Ground Circuit Check. NO:Wire(s) without voltage are open. Repair wire or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) ( 5 ) Ground Circuit Check
Action: Ignition OFF. Disconnect transmission control unit (TCU) connector. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check circuit G12 BLK for ground at pins 1 and 4 on TCU harness connector. Is ground present?
Result: YES:Go to CAN Circuit Check. NO:Circuit G12 BLK is open. Repair circuit or replace harness. See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) ( 6 ) CAN Circuit Check
Action: Perform CAN Circuit Testing. (Group 9015-20.) Does CAN circuit test good?
Result: YES:Replace the transmission control unit (TCU). NO:Repair CAN circuit.
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Section 9001 page 797
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Section 9001 - DIAGNOSTICS
Group 40: CAN Monitor Unit (CMU) Diagnostic Trouble Codes
002033.19- CCU CAN Comm CAN Error 215
Controller area network (CAN) communication error; the CAN monitor unit (CMU) lost communication with the chassis control unit (CCU).
CCU CAN Data Fault Diagnostic Procedure Alarm Level: Caution Icon (yellow) Additional References: For additional information, See CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-10.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20.) NO:Go to Controller Sensors Check. ( 2 ) Controller Sensors Check
Action: Connect Service ADVISOR ™ . See Service ADVISOR™ Connection Procedure . (Group 9015-20.) View CCU input sensor data on Service ADVISOR™. Are all CCU sensor values displayed?
Result: YES:Program CAN monitor unit (CMU). NO:Go to Fuse Check. ( 3 ) Fuse Check
Action: Ignition OFF. Remove fuses (F11 and F25). See Fuse and Relay Specifications . (Group 9015-10.) Check fuses (F11 and F25) for continuity. Is continuity indicated?
Result: YES:Go to Voltage Check. NO:Fuse without continuity indicated is faulty. Replace fuse. ( 4 ) Voltage Check
Action: Ignition OFF. Disconnect CCU connector. See Cab Harness (W3) Component Location . (Group 9015-10.) Ignition ON. Check for voltage at the following pins on TCU connector: 23 (circuit 901 GRN) 45 (circuit 900 RED) <- Go to Section TOC
Section 9001 page 798
TM12406-OPERATION AND TEST MANUAL
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Section 9001 - DIAGNOSTICS
68 (circuit 901 GRN) Is system voltage (approximately 24 volts) present at all pins?
Result: YES:Go to Ground Circuit Check. NO:Circuit without voltage present is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) ( 5 ) Ground Circuit Check
Action: Ignition OFF. Disconnect TCU connector. See Transmission Control Harness (W4) Component Location . (Group 9015-10.) Check for ground at pin 46 (circuit 902 BLK) on TCU connector. Is ground present?
Result: YES:Go to CAN Circuit Check. NO:Circuit without ground present is open. Repair circuit or replace harness. See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) See Transmission Control Harness (W4) Wiring Diagram . (Group 9015-10.) ( 6 ) CAN Circuit Check
Action: Test controller area network (CAN) circuit. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Reprogram chassis control unit (CCU). NO:Repair CAN circuit.
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Section 9001 page 799
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Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Group 50 - 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes 000629.12- Controller Fault Bad Device 354
The 25-button sealed switch module (SSM) (OC3) has a watchdog timeout.
Controller Fault Bad Device Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 000629.12 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 000629.12 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 800
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
002033.09- CCU CAN Communication Fault 354
The 25-button sealed switch module (SSM) (OC3) has lost communication with the chassis control unit (CCU).
CCU CAN Communication Fault Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20). NO:Go to CAN Circuit Check. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Reset Controller. NO:Repair CAN circuit. ( 3 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 002033.09 present?
Result: YES:Go to Controller Check. NO:Checks complete. ( 4 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). <- Go to Section TOC
Section 9001 page 801
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Are correct values displayed in the CMU?
Result: YES:Go to next step in this check. NO:Go to Reprogram Controller.
Action: Reprogram 25-button SSM (OC3). Is DTC 002033.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete. ( 5 ) Reprogram Controller
Action: Reprogram chassis control unit (CCU). Is DTC 002033.09 present?
Result: YES:Replace chassis control unit (CCU). NO:Checks complete.
<- Go to Section TOC
Section 9001 page 802
TM12406-OPERATION AND TEST MANUAL
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Section 9001 - DIAGNOSTICS
002634.04- Ignition Relay Out Voltage Low 354
The ignition relay output from the 25-button SSM (OC3) is short to ground.
Ignition Relay Out Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20). NO:Go to Diode Check. ( 2 ) Diode Check
Action: Turn battery disconnect OFF. Remove ignition relay diode (V1). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check continuity of diode (V1). Reverse leads and check continuity of diode (V1) again. Is continuity indicated in one direction and not the other?
Result: YES:Go to Ignition Relay Check. NO:Replace ignition relay diode (V1). ( 3 ) Ignition Relay Check
Action: Turn battery disconnect OFF. Remove ignition relay (K1). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance across the coil (pins 1 and 2) of relay (K1). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Short Circuit Check. NO:Replace ignition relay (K1). ( 4 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect the 25-button SSM (OC3) 6-pin connector. See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit E02 WHT for ground at pin 3 on connector. <- Go to Section TOC
Section 9001 page 803
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Is ground present?
Result: YES:Circuit E02 WHT is short to ground. Repair circuit or replace harness. See Front Frame Harness (W2) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Go to Harness Check. ( 5 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect the cab harness-to-front frame harness 9-pin connector (X52). See Front Frame Harness (W2) Component Location . (Group 9015-10.) On cab harness side of connector (X52), check for continuity between pin V (circuit E02 WHT) of connector (X52) and all other pins on connector. On front frame harness side of connector (X52), check for continuity between pin V (circuit E02 WHT) of connector (X52) and all other pins on connector. Is continuity indicated?
Result: YES:Circuit that indicated continuity to another pin is short. Repair circuit or replace harness. See Front Frame Harness (W2) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Go to Reset Controller. ( 6 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 002634.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete.
<- Go to Section TOC
Section 9001 page 804
TM12406-OPERATION AND TEST MANUAL
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Section 9001 - DIAGNOSTICS
002634.05- Ignition Relay Out Current Low 354
The ignition relay output from the 25-button SSM (OC3) is open.
Ignition Relay Out Current Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20). NO:Go to Ignition Relay Check. ( 2 ) Ignition Relay Check
Action: Turn battery disconnect OFF. Remove ignition relay (K1). See Front Frame Harness (W2) Component Location . (Group 9015-10.) Measure resistance across the coil (pins 1 and 2) of relay (K1). Compare resistance to specification. See Electrical Component Specifications . (Group 9015-20.) Is resistance to specification?
Result: YES:Go to Open Circuit Check. NO:Replace ignition relay (K1). ( 3 ) Open Circuit Check
Action: Turn battery disconnect OFF. Disconnect the 25-button SSM (OC3) 6-pin connector. See Cab Harness (W3) Component Location . (Group 9015-10.) Disconnect the ignition relay (K1) 2-pin connector. See Front Frame Harness (W2) Component Location . (Group 9015-10.) Check circuit E02 WHT for continuity between pin 3 of SSM 6-pin connector and pin 1 of ignition relay 2-pin connector. Check circuit G02 BLK for continuity between pin 2 of ignition relay 2-pin connector and ground. Is continuity indicated?
Result: YES:Go to Reset Controller. NO:Circuit without continuity indicated is open. Repair circuit or replace harness. See Front Frame Harness (W2) Component Location . (Group 9015-10.) See Front Frame Harness (W2) Component Location . (Group 9015-10.) See Cab Harness (W3) Component Location . (Group 9015-10.) ( 4 ) Reset Controller
<- Go to Section TOC
Section 9001 page 805
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Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 002634.05 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete.
<- Go to Section TOC
Section 9001 page 806
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Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Section 9001 - DIAGNOSTICS
003997.04- Wake Up Output Voltage Low 354
The four-way flasher output from the 25-button SSM (OC3) is short to ground.
Wake Up Output Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20). NO:Go to Short Circuit Check. ( 2 ) Short Circuit Check
Action: Turn battery disconnect OFF. Disconnect the 25-button SSM (OC3) 6-pin connector. See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit M25 PUR for ground at pin 4 on connector. Is ground present?
Result: YES:Circuit M25 PUR is short to ground. Repair circuit or replace harness. See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Go to Harness Check. ( 3 ) Harness Check
Action: Turn battery disconnect OFF. Disconnect the chassis control unit (CCU) 53-pin connector (J3) (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check for continuity between pin 19 (circuit M25 PUR) of connector (X23) and all other pins on connector. Is continuity indicated?
Result: YES:Circuit that indicated continuity to another pin is short. Repair circuit or replace harness. See Cab Harness (W3) Component Location . (Group 9015-10.) NO:Go to Reset Controller. ( 4 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. <- Go to Section TOC
Section 9001 page 807
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Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 003997.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete.
<- Go to Section TOC
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Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Section 9001 - DIAGNOSTICS
003997.05- Wake Up Output Current Low 354
The four-way flasher output from the 25-button SSM (OC3) is open.
Wake Up Output Current Low Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20). NO:Go to Ignition Relay Check. ( 2 ) Open Circuit Check
Action: Turn battery disconnect OFF. Disconnect the 25-button SSM (OC3) 6-pin connector and chassis control unit (CCU) 53-pin connector (J3) (X23). See Cab Harness (W3) Component Location . (Group 9015-10.) Check circuit M25 PUR for continuity between pin 4 of SSM 6-pin connector and pin 19 of CCU connector (X23). Is continuity indicated?
Result: YES:Go to Reset Controller. NO:Circuit M25 PUR is open. Repair circuit or replace harness. See Cab Harness (W3) Component Location . (Group 9015-10.) ( 3 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 003997.05 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 520752.04- Button 17 Voltage Low 354
Rear windshield washer switch is stuck closed. <- Go to Section TOC
Section 9001 page 809
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Button 17 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 520752.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push rear windshield washer switch. Is DTC 520752.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 520752.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push rear windshield washer switch. Is DTC 520752.04 present?
Result: YES:Replace 25-button SSM (OC3). <- Go to Section TOC
Section 9001 page 810
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
NO:Check complete.
<- Go to Section TOC
Section 9001 page 811
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
520752.09- Button 17 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the rear windshield washer switch was pushed.
Button 17 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push rear windshield washer switch. Is DTC 520752.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 812
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push rear windshield washer switch. Is DTC 520752.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 520753.04- Button 18 Voltage Low 354
Rear windshield wiper switch is stuck closed.
Button 18 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 520753.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push rear windshield wiper switch. Is DTC 520753.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 520753.04 present? <- Go to Section TOC
Section 9001 page 813
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push rear windshield wiper switch. Is DTC 520753.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 814
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
520753.09- Button 18 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the rear windshield wiper switch was pushed.
Button 18 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push rear windshield wiper switch. Is DTC 520753.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 815
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push rear windshield wiper switch. Is DTC 520753.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 520754.04- Button 19 Voltage Low 354
Gear hold switch is stuck closed.
Button 19 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 520754.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push gear hold switch. Is DTC 520754.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 520754.04 present? <- Go to Section TOC
Section 9001 page 816
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push gear hold switch. Is DTC 520754.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 817
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
520754.09- Button 19 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the gear hold switch was pushed.
Button 19 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push gear hold switch. Is DTC 520754.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 818
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push gear hold switch. Is DTC 520754.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 520755.04- Button 20 Voltage Low 354
Dump body UP switch is stuck closed.
Button 20 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 520755.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push dump body UP switch. Is DTC 520755.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 520755.04 present? <- Go to Section TOC
Section 9001 page 819
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push dump body UP switch. Is DTC 520755.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 820
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
520755.09- Button 20 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the dump body UP switch was pushed.
Button 20 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push dump body UP switch. Is DTC 520755.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 821
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push dump body UP switch. Is DTC 520755.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523335.04- Button 25 Voltage Low 354
Dump body DOWN switch is stuck closed.
Button 25 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523335.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push dump body DOWN switch. Is DTC 523335.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523335.04 present? <- Go to Section TOC
Section 9001 page 822
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push dump body DOWN switch. Is DTC 523335.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 823
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523335.09- Button 25 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the dump body DOWN switch was pushed.
Button 25 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push dump body DOWN switch. Is DTC 523335.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 824
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push dump body DOWN switch. Is DTC 52335.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523336.04- Button 24 Voltage Low 354
Retarder increase switch is stuck closed.
Button 24 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523336.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push retarder increase switch. Is DTC 523336.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523336.04 present? <- Go to Section TOC
Section 9001 page 825
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push retarder increase switch. Is DTC 523336.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 826
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523336.09- Button 24 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the retarder increase switch was pushed.
Button 24 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push retarder increase switch. Is DTC 523336.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 827
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push retarder increase switch. Is DTC 52336.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523338.04- Button 23 Voltage Low 354
Retarder decrease switch is stuck closed.
Button 23 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523338.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push retarder decrease switch. Is DTC 523338.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523338.04 present? <- Go to Section TOC
Section 9001 page 828
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push retarder decrease switch. Is DTC 523338.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 829
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523338.09- Button 23 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the retarder decrease switch was pushed.
Button 23 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push retarder decrease switch. Is DTC 523338.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 830
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push retarder decrease switch. Is DTC 52338.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523339.04- Button 22 Voltage Low 354
Auto differential lock (ADL) switch is stuck closed.
Button 22 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523339.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push auto differential lock (ADL) switch. Is DTC 523339.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523339.04 present? <- Go to Section TOC
Section 9001 page 831
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push auto differential lock (ADL) switch. Is DTC 523339.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 832
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523339.09- Button 22 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the auto differential lock (ADL) switch was pushed.
Button 22 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push auto differential lock (ADL) switch. Is DTC 523339.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 833
TM12406-OPERATION AND TEST MANUAL
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Section 9001 - DIAGNOSTICS
Action: Reprogram chassis control unit (CCU). Push auto differential lock (ADL) switch. Is DTC 52339.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523340.04- Button 21 Voltage Low 354
Inter-axle differential lock (IDL) switch is stuck closed.
Button 21 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523340.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push inter-axle differential lock (IDL) switch. Is DTC 523340.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523340.04 present? <- Go to Section TOC
Section 9001 page 834
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push inter-axle differential lock (IDL) switch. Is DTC 523340.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 835
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523340.09- Button 21 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the inter-axle differential lock (IDL) switch was pushed.
Button 21 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push inter-axle differential lock (IDL) switch. Is DTC 523340.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 836
TM12406-OPERATION AND TEST MANUAL
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Section 9001 - DIAGNOSTICS
Action: Reprogram chassis control unit (CCU). Push inter-axle differential lock (IDL) switch. Is DTC 52340.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523849.04- Button 16 Voltage Low 354
Operator speed control decrease switch is stuck closed.
Button 16 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523849.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push operator speed control decrease switch. Is DTC 523849.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523849.04 present? <- Go to Section TOC
Section 9001 page 837
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push operator speed control decrease switch. Is DTC 523849.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 838
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523849.09- Button 16 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the operator speed control decrease switch was pushed.
Button 16 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push operator speed control decrease switch. Is DTC 523849.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 839
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push operator speed control decrease switch. Is DTC 523849.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523850.04- Button 15 Voltage Low 354
Reverse gear select switch is stuck closed.
Button 15 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523850.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push reverse gear select switch. Is DTC 523850.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523850.04 present? <- Go to Section TOC
Section 9001 page 840
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push reverse gear select switch. Is DTC 523850.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 841
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523850.09- Button 15 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the reverse gear select switch was pushed.
Button 15 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push reverse gear select switch. Is DTC 523850.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 842
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push reverse gear select switch. Is DTC 523850.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523852.04- Button 14 Voltage Low 354
Gear range decrease switch is stuck closed.
Button 14 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523852.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push gear range decrease switch. Is DTC 523852.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523852.04 present? <- Go to Section TOC
Section 9001 page 843
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push gear range decrease switch. Is DTC 523852.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 844
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523852.09- Button 14 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the gear range decrease switch was pushed.
Button 14 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push gear range decrease switch. Is DTC 523852.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 845
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push gear range decrease switch. Is DTC 523852.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523854.04- Button 13 Voltage Low 354
Front windshield wiper switch is stuck closed.
Button 13 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523854.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push front windshield wiper switch. Is DTC 523854.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523854.04 present? <- Go to Section TOC
Section 9001 page 846
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push front windshield wiper switch. Is DTC 523854.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 847
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523854.09- Button 13 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the front windshield wiper switch was pushed.
Button 13 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push front windshield wiper switch. Is DTC 523854.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 848
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push front windshield wiper switch. Is DTC 523854.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523855.04- Button 12 Voltage Low 354
Front windshield washer switch is stuck closed.
Button 12 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523855.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push front windshield washer switch. Is DTC 523855.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523855.04 present? <- Go to Section TOC
Section 9001 page 849
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push front windshield washer switch. Is DTC 523855.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 850
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523855.09- Button 12 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the front windshield washer switch was pushed.
Button 12 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push front windshield washer switch. Is DTC 523855.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 851
TM12406-OPERATION AND TEST MANUAL
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Section 9001 - DIAGNOSTICS
Action: Reprogram chassis control unit (CCU). Push front windshield washer switch. Is DTC 523855.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523856.04- Button 11 Voltage Low 354
Operator speed control increase switch is stuck closed.
Button 11 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523856.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push operator speed control increase switch. Is DTC 523856.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523856.04 present? <- Go to Section TOC
Section 9001 page 852
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push operator speed control increase switch. Is DTC 523856.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 853
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523856.09- Button 11 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the operator speed control increase switch was pushed.
Button 11 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push operator speed control increase switch. Is DTC 523856.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 854
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push operator speed control increase switch. Is DTC 523856.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523857.04- Button 10 Voltage Low 354
Neutral selection switch is stuck closed.
Button 10 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523857.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push neutral selection switch. Is DTC 523857.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523857.04 present? <- Go to Section TOC
Section 9001 page 855
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push neutral selection switch. Is DTC 523857.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 856
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523857.09- Button 10 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the neutral selection switch was pushed.
Button 10 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push neutral selection switch. Is DTC 523857.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 857
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push neutral selection switch. Is DTC 523857.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523858.04- Button 9 Voltage Low 354
Gear range increase switch is stuck closed.
Button 9 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523858.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push gear range increase switch. Is DTC 523858.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523858.04 present? <- Go to Section TOC
Section 9001 page 858
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push gear range increase switch. Is DTC 523858.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 859
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523858.09- Button 9 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the gear range increase switch was pushed.
Button 9 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push gear range increase switch. Is DTC 523858.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 860
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push gear range increase switch. Is DTC 523858.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523860.04- Button 8 Voltage Low 354
Auto dump body settings switch is stuck closed.
Button 8 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523860.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push auto dump body settings switch. Is DTC 523860.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523860.04 present? <- Go to Section TOC
Section 9001 page 861
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push auto dump body settings switch. Is DTC 523860.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 862
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523860.09- Button 8 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the auto dump body settings switch was pushed.
Button 8 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push auto dump body settings switch. Is DTC 523860.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 863
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Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push auto dump body settings switch. Is DTC 523860.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523861.04- Button 7 Voltage Low 354
Descent control switch is stuck closed.
Button 7 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523861.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push descent control switch. Is DTC 523861.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523861.04 present? <- Go to Section TOC
Section 9001 page 864
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Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push descent control switch. Is DTC 523861.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 865
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Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523861.09- Button 7 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the descent control switch was pushed.
Button 7 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push descent control switch. Is DTC 523861.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 866
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Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Section 9001 - DIAGNOSTICS
Action: Reprogram chassis control unit (CCU). Push descent control switch. Is DTC 523861.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523862.04- Button 6 Voltage Low 354
Operator speed control select switch is stuck closed.
Button 6 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523862.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push operator speed control select switch. Is DTC 523862.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523862.04 present? <- Go to Section TOC
Section 9001 page 867
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push operator speed control select switch. Is DTC 523862.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 868
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523862.09- Button 6 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the operator speed control select switch was pushed.
Button 6 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push operator speed control select switch. Is DTC 523862.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 869
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push operator speed control select switch. Is DTC 523862.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523863.04- Button 5 Voltage Low 354
Forward gear select switch is stuck closed.
Button 5 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523863.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push forward gear select switch. Is DTC 523863.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523863.04 present? <- Go to Section TOC
Section 9001 page 870
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push forward gear select switch. Is DTC 523863.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 871
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523863.09- Button 5 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the forward gear select switch was pushed.
Button 5 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push forward gear select switch. Is DTC 523863.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 872
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push forward gear select switch. Is DTC 523863.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523864.04- Button 4 Voltage Low 354
Park brake switch is stuck closed.
Button 4 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523864.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push park brake switch. Is DTC 523864.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523864.04 present? <- Go to Section TOC
Section 9001 page 873
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push park brake switch. Is DTC 523864.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 874
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523864.09- Button 4 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the park brake switch was pushed.
Button 4 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push park brake switch. Is DTC 523864.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 875
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push park brake switch. Is DTC 523864.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523865.04- Button 3 Voltage Low 354
Four-way flashers switch is stuck closed.
Button 3 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523865.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push four-way flashers switch. Is DTC 523865.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523865.04 present? <- Go to Section TOC
Section 9001 page 876
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push four-way flashers switch. Is DTC 523865.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 877
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523865.09- Button 3 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the four-way flashers switch was pushed.
Button 3 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push four-way flashers switch. Is DTC 523865.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 878
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push four-way flashers switch. Is DTC 523865.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523867.04- Button 2 Voltage Low 354
Engine stop switch is stuck closed.
Button 2 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523867.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push engine stop switch. Ignition ON. Is DTC 523867.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). <- Go to Section TOC
Section 9001 page 879
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Is DTC 523867.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push engine stop switch. Ignition ON. Is DTC 523867.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 880
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523867.09- Button 2 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the engine stop switch was pushed.
Button 2 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push engine stop switch. Is DTC 523867.09 present?
Result: YES:Go to CAN Circuit Check. NO:Go to next step in this check.
Action: Push engine stop switch. Ignition ON. Is DTC 523867.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
<- Go to Section TOC
Section 9001 page 881
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller
Action: Reprogram chassis control unit (CCU). Push engine stop switch. Ignition ON. Is DTC 523867.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete. 523868.04- Button 1 Voltage Low 354
Engine start switch is stuck closed.
Button 1 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition power is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523868.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
<- Go to Section TOC
Section 9001 page 882
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
Action: Push engine start switch. Is DTC 523868.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 25-button SSM (OC3). Is DTC 523868.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Go to next step in this check.
Action: Push engine start switch. Is DTC 523868.04 present?
Result: YES:Replace 25-button SSM (OC3). NO:Check complete.
<- Go to Section TOC
Section 9001 page 883
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 50: 25-Button Sealed Switch Module SSM (OC3) Diagnostic Trouble Codes
523868.09- Button 1 Bad Update Rate 354
The 25-button sealed switch module (SSM) (OC3) did not receive LED control message from chassis control unit (CCU) after the engine start switch was pushed.
Button 1 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 25-button sealed switch module (SSM) (OC3) will not store diagnostic trouble codes; when ignition is cycled, the 25-button SSM (OC3) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Push engine start switch. Is DTC 523868.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 25-button SSM (OC3). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller
<- Go to Section TOC
Section 9001 page 884
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Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push engine start switch. Is DTC 523868.09 present?
Result: YES:Replace 25-button SSM (OC3). NO:Checks complete.
<- Go to Section TOC
Section 9001 page 885
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Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Group 60 - 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes 000629.12- Controller Fault Bad Device 380
The 15-button sealed switch module (SSM) (OC4) has a watchdog timeout.
Controller Fault Bad Device Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 000629.12 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 000629.12 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 886
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
002033.09- CCU CAN Communication Fault 380
The 15-button sealed switch module (SSM) (OC4) has lost communication with the chassis control unit (CCU).
CCU CAN Communication Fault Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Intermittent Check
Action: Does DTC periodically “go away”?
Result: YES:DTC is intermittent. See Intermittent Diagnostic Trouble Code (DTC) Diagnostics . (Group 9015-20). NO:Go to CAN Circuit Check. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Reset Controller. NO:Repair CAN circuit. ( 3 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 002033.09 present?
Result: YES:Go to Controller Check. NO:Checks complete. ( 4 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). <- Go to Section TOC
Section 9001 page 887
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Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Are correct values displayed in the CMU?
Result: YES:Go to next step in this check. NO:Go to Reprogram Controller.
Action: Reprogram 15-button SSM (OC4). Is DTC 002033.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete. ( 5 ) Reprogram Controller
Action: Reprogram chassis control unit (CCU). Is DTC 002033.09 present?
Result: YES:Replace chassis control unit (CCU). NO:Checks complete. 523850.04- Button 15 Voltage Low 380
Blower speed decrease switch is stuck closed.
Button 15 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523850.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check. <- Go to Section TOC
Section 9001 page 888
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Action: Push blower speed decrease switch. Is DTC 523850.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523850.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push blower speed decrease switch. Is DTC 523850.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 889
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Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523850.09- Button 15 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the blower speed decrease switch was pushed.
Button 15 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push blower speed decrease switch. Is DTC 523850.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 890
TM12406-OPERATION AND TEST MANUAL
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Section 9001 - DIAGNOSTICS
Action: Reprogram chassis control unit (CCU). Push blower speed decrease switch. Is DTC 523850.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete. 523852.04- Button 14 Voltage Low 380
Cab air temperature decrease switch is stuck closed.
Button 14 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523852.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push cab air temperature decrease switch. Is DTC 523852.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523852.04 present? <- Go to Section TOC
Section 9001 page 891
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push cab air temperature decrease switch. Is DTC 523852.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 892
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523852.09- Button 14 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the cab air temperature decrease switch was pushed.
Button 14 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push cab air temperature decrease switch. Is DTC 523852.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 893
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push cab air temperature decrease switch. Is DTC 523852.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete. 523854.04- Button 13 Voltage Low 380
Heated seat switch is stuck closed.
Button 13 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523854.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push heated seat switch. Is DTC 523854.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523854.04 present? <- Go to Section TOC
Section 9001 page 894
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push heated seat switch. Is DTC 523854.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 895
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523854.09- Button 13 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the heated seat switch was pushed.
Button 13 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push heated seat switch. Is DTC 523854.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 896
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push heated seat switch. Is DTC 523854.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete. 523855.04- Button 12 Voltage Low 380
Blower speed increase switch is stuck closed.
Button 12 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523855.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push blower speed increase switch. Is DTC 523855.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523855.04 present? <- Go to Section TOC
Section 9001 page 897
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push blower speed increase switch. Is DTC 523855.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 898
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523855.09- Button 12 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the blower speed increase switch was pushed.
Button 12 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push blower speed increase switch. Is DTC 523855.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 899
TM12406-OPERATION AND TEST MANUAL
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Section 9001 - DIAGNOSTICS
Action: Reprogram chassis control unit (CCU). Push blower speed increase switch. Is DTC 523855.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete. 523856.04- Button 11 Voltage Low 380
Cab air temperature increase switch is stuck closed.
Button 11 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523856.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push cab air temperature increase switch. Is DTC 523856.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523856.04 present? <- Go to Section TOC
Section 9001 page 900
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push cab air temperature increase switch. Is DTC 523856.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 901
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523856.09- Button 11 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the cab air temperature increase switch was pushed.
Button 11 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push cab air temperature increase switch. Is DTC 523856.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 902
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push cab air temperature increase switch. Is DTC 523856.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete. 523857.04- Button 10 Voltage Low 380
Feet control switch is stuck closed.
Button 10 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523857.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push feet control switch. Is DTC 523857.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523857.04 present? <- Go to Section TOC
Section 9001 page 903
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push feet control switch. Is DTC 523857.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 904
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523857.09- Button 10 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the feet control switch was pushed.
Button 10 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push feet control switch. Is DTC 523857.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 905
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push feet control switch. Is DTC 523857.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete. 523858.04- Button 9 Voltage Low 380
Air conditioner switch is stuck closed.
Button 9 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523858.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push air conditioner switch. Is DTC 523858.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523858.04 present? <- Go to Section TOC
Section 9001 page 906
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push air conditioner switch. Is DTC 523858.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 907
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523858.09- Button 9 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the air conditioner switch was pushed.
Button 9 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push air conditioner switch. Is DTC 523858.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 908
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push air conditioner switch. Is DTC 523858.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete. 523860.04- Button 8 Voltage Low 380
Cab air recirculation switch is stuck closed.
Button 8 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523860.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push cab air recirculation switch. Is DTC 523860.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523860.04 present? <- Go to Section TOC
Section 9001 page 909
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push cab air recirculation switch. Is DTC 523860.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 910
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523860.09- Button 8 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the cab air recirculation switch was pushed.
Button 8 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push cab air recirculation switch. Is DTC 523860.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 911
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push cab air recirculation switch. Is DTC 523860.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete. 523861.04- Button 7 Voltage Low 380
Defrost/mid vent control switch is stuck closed.
Button 7 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523861.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push defrost/mid vent control switch. Is DTC 523861.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523861.04 present? <- Go to Section TOC
Section 9001 page 912
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push defrost/mid vent control switch. Is DTC 523861.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 913
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523861.09- Button 7 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the defrost/mid vent control switch was pushed.
Button 7 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push defrost/mid vent control switch. Is DTC 523861.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 914
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push defrost/mid vent control switch. Is DTC 523861.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete. 523862.04- Button 6 Voltage Low 380
Stair light switch is stuck closed.
Button 6 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523862.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push stair light switch. Is DTC 523862.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523862.04 present? <- Go to Section TOC
Section 9001 page 915
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push stair light switch. Is DTC 523862.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 916
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523862.09- Button 6 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the stair light switch was pushed.
Button 6 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push stair light switch. Is DTC 523862.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 917
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push stair light switch. Is DTC 523862.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete. 523863.04- Button 5 Voltage Low 380
Articulation reverse light switch is stuck closed.
Button 5 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523863.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push articulation reverse light switch. Is DTC 523863.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523863.04 present? <- Go to Section TOC
Section 9001 page 918
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Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push articulation reverse light switch. Is DTC 523863.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 919
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Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523863.09- Button 5 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the articulation reverse light switch was pushed.
Button 5 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push articulation reverse light switch. Is DTC 523863.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 920
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push articulation reverse light switch. Is DTC 523863.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete. 523864.04- Button 4 Voltage Low 380
Front work light switch is stuck closed.
Button 4 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523864.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push front work light switch. Is DTC 523864.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523864.04 present? <- Go to Section TOC
Section 9001 page 921
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Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push front work light switch. Is DTC 523864.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
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Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523864.09- Button 4 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the front work light switch was pushed.
Button 4 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push front work light switch. Is DTC 523864.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 923
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push front work light switch. Is DTC 523864.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete. 523865.04- Button 3 Voltage Low 380
Heated mirror switch is stuck closed.
Button 3 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523865.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push heated mirror switch. Is DTC 523865.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523865.04 present? <- Go to Section TOC
Section 9001 page 924
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Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push heated mirror switch. Is DTC 523865.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 925
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523865.09- Button 3 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the heated mirror switch was pushed.
Button 3 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push heated mirror switch. Is DTC 523865.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 926
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push heated mirror switch. Is DTC 523865.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete. 523867.04- Button 2 Voltage Low 380
Rotary beacon light switch is stuck closed.
Button 2 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523867.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push rotary beacon light switch. Is DTC 523867.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523867.04 present? <- Go to Section TOC
Section 9001 page 927
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push rotary beacon light switch. Is DTC 523867.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 928
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523867.09- Button 2 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the rotary beacon light switch was pushed.
Button 2 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push rotary beacon light switch. Is DTC 523867.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 929
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Action: Reprogram chassis control unit (CCU). Push rotary beacon light switch. Is DTC 523867.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete. 523868.04- Button 1 Voltage Low 380
Headlight switch is stuck closed.
Button 1 Voltage Low Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition power is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Is DTC 523868.04 present?
Result: YES:Go to Program Controller. NO:Go to next step in this check.
Action: Push headlight switch. Is DTC 523868.04 present?
Result: YES:Go to Program Controller. NO:Check complete. ( 2 ) Program Controller
Action: Reprogram 15-button SSM (OC4). Is DTC 523868.04 present? <- Go to Section TOC
Section 9001 page 930
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
Result: YES:Replace 15-button SSM (OC4). NO:Go to next step in this check.
Action: Push headlight switch. Is DTC 523868.04 present?
Result: YES:Replace 15-button SSM (OC4). NO:Check complete.
<- Go to Section TOC
Section 9001 page 931
TM12406-OPERATION AND TEST MANUAL
Section 9001 - DIAGNOSTICS
Group 60: 15-Button Sealed Switch Module SSM (OC4) Diagnostic Trouble Codes
523868.09- Button 1 Bad Update Rate 354
The 15-button sealed switch module (SSM) (OC4) did not receive LED control message from chassis control unit (CCU) after the headlight switch was pushed.
Button 1 Bad Update Rate Diagnostic Procedure Alarm Level: Check Service Code Additional References: For additional information, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 1 ) Reset Controller
Action: →NOTE: The 15-button sealed switch module (SSM) (OC4) will not store diagnostic trouble codes; when ignition is cycled, the 15-button SSM (OC4) will reset and all codes will be lost. Document all diagnostic codes. Ignition OFF. Wait 20 seconds. Ignition ON. Push headlight switch. Is DTC 523868.09 present?
Result: YES:Go to CAN Circuit Check. NO:Checks complete. ( 2 ) CAN Circuit Check
Action: Perform Controller Area Network (CAN) Circuit Test . (Group 9015-20). Does CAN circuit test good?
Result: YES:Go to Controller Check. NO:Repair CAN circuit. ( 3 ) Controller Check
Action: Ignition ON. View coolant temperature and fuel level values on the CAN monitor unit (CMU). Are correct values displayed in the CMU?
Result: YES:Reprogram 15-button SSM (OC4). NO:Go to Reprogram Controller. ( 4 ) Reprogram Controller <- Go to Section TOC
Section 9001 page 932
TM12406-OPERATION AND TEST MANUAL
OPERATIONAL CHECKOUT PROCEDURE
(g) by Belgreen v2.0
Action: Reprogram chassis control unit (CCU). Push headlight switch. Is DTC 523868.09 present?
Result: YES:Replace 15-button SSM (OC4). NO:Checks complete.
<- Go to Section TOC
Section 9005 page 933
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TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE Table of contents Group 10 - Operational Checkout Procedure ....................................................................................... 1 Operational Checks—Ignition ON, Engine ON Checks ........................................................................... 1
<- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
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 the operator seat. Complete visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring, etc.) before performing the checkout. Most checks will require machine systems to be at normal operating temperatures and a level area with adequate space to operate the machine. Some checks may require varied surfaces. No special tools are necessary to perform the checkout. If no problem is found, go to the next check. If a problem is indicated, an additional check or repair procedure will be suggested.
Diagnostic Trouble Code Check ( 1 ) Display and Clear Trouble Codes
Action: Always check for diagnostic trouble codes (DTCs) and correct them before performing the operational checkout. Check for active and stored diagnostic trouble codes (DTCs). Diagnostic trouble codes can be displayed by using one of the following methods. CAN monitor unit (CMU) To access DTCs using the CMU, see CAN Monitor Unit (CMU)—Main Menu—Diagnostics—Codes . (Operator’s Manual.) Service ADVISOR ™ Diagnostic Application To access DTCs using Service ADVISOR™ diagnostic application, see Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) sss: Are diagnostic trouble codes present?
Result: YES:Correct all active DTCs before proceeding. NO:Continue with operational checkout.
Operational Checks—Ignition OFF, Engine OFF Checks ( 1 ) Cold Start Aid Check
Action:
<- Go to Section TOC
Section 9005 page 1
TM12406-OPERATION AND TEST MANUAL
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
CAUTION: Prevent possible injury from exploding container. Starting fluid is highly flammable. Keep container away from heat, sparks and open flame. Contents are pressurized. DO NOT puncture or incinerate container. Remove can from machine if engine does not need starting fluid.
Contents Under Pressure
Open the engine hood. Check position of canister. Inspect plastic line from bottom of start aid to air intake manifold. sss: Are any kinks or breaks in the line? sss: Are the line fittings connected securely?
Result: YES:Replace plastic line if kinks are present. Tighten any loose connections. NO:Go to next step in this check.
Action: Check for dot on start aid nozzle in air intake manifold. sss: Is dot at 9 o’clock position on the fitting of air intake manifold?
Result: YES:Checks complete. NO:Adjust fitting so dot is in correct position. ( 2 ) Seat Control Checks
Action: →NOTE: For seat adjustment procedures, see Operator Seat and Instructional Seat . (Operator’s Manual.) sss: Does seat rise and lower easily? <- Go to Section TOC
Section 9005 page 2
TM12406-OPERATION AND TEST MANUAL
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
sss: Does seat angle change easily? sss: Does lever move easily to unlock seat support? sss: Does seat move forward and rearward easily? sss: Does lever lock seat support in position when released? sss: Does seat back tilt forward and rearward easily? sss: Does lever unlock and lock easily to hold seat back in position?
Result: YES:Checks complete. NO:Repair seat linkage as needed. ( 3 ) Horn Circuit Check
Action: LEGEND: 1
Horn Switch
Horn Switch Location Push horn switch (1). sss: Does horn activate?
Result: YES:Check complete. NO:Check 10-amp fuse (F3) for continuity. See Fuse and Relay Specifications . (Group 9015-10.) If 10-amp fuse (F3) is OK, check horn wiring and connections. See Front Frame Harness (W2) Wiring Diagram and see Front Frame Harness (W2) Component Location . (Group 9015-10.) ( 4 ) Hazard Lights Circuit and 25-Button Sealed Switch Module (SSM) LEDs Check
Action:
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Section 9005 page 3
TM12406-OPERATION AND TEST MANUAL
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Hazard Light Switch Push and release hazard light switch on 25-button SSM. sss: Do all SSM switch LEDs come on when the hazard light switch is pushed? sss: After approximately 1 second, do all SSM switch LEDs turn off and hazard light switch LED remain on? sss: Do the left and right turn lights, both front and rear, flash?
Result: YES:Go to next step in this check. NO:Check 10-amp fuse (F1) and 15-amp fuse (F17). See Fuse and Relay Specifications . (Group 9015-10.) If fuse is OK, check 25-button SSM (OC3) wiring and circuits. See Cab Harness (W3) Wiring Diagram and see Cab Harness (W3) Component Location . (Group 9015-10.)
Action: Push and release the hazard light switch again. sss: Do the left and right turn lights, both front and rear, turn off? sss: Does the hazard light switch LED turn off?
Result: YES:Checks complete. NO:Check 25-button SSM (OC3) wiring and circuits. See Cab Harness (W3) Wiring Diagram and see Cab Harness (W3) Component Location . (Group 9015-10.)
Operational Checks—Ignition ON, Engine OFF Checks ( 1 ) Gauges and Indicator Lights Check
Action: Make sure battery disconnect switch is ON.
<- Go to Section TOC
Section 9005 page 4
TM12406-OPERATION AND TEST MANUAL
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Engine Start Switch Push engine start switch on the 25-button sealed switch module (SSM) once; switched power ON. →NOTE: If security is enabled, the Security screen will appear when the ignition is turned ON. Enter correct personal identification number (PIN) to continue. Observe the CAN monitor unit (CMU) gauges and warning lights as the CMU powers up. sss: Does the left LED on the engine start switch come ON? sss: Do all warning lights on CAN monitor unit (CMU) come ON or flash? sss: Do all gauges and speedometer on CMU move through full range of motion? sss: Does the “fasten seat belt” image appear on the CMU message display? sss: Does audible alarm activate? sss: After 3 seconds, do all gauges go to normal operation mode? Does the CMU message display show the default display screen? Do all CMU warning lights, battery charge, and park brake go OFF? sss: Does the audible alarm stop beeping?
Result: YES:Go to next check. NO:Check circuit breakers and fuses. Reset tripped breakers and/or replace fuses as necessary. See Fuse and Relay Specifications . (Group 9015-10.) Check indicator bulbs. Replace if necessary.If circuit breakers, fuses, and bulbs are good, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) ( 2 ) Cab System Checks
Action:
<- Go to Section TOC
Section 9005 page 5
TM12406-OPERATION AND TEST MANUAL
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
15-Button Sealed Switch Module (SSM) LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Headlight Switch Rotary Beacon Light Switch (if equipped) Heated Mirror Switch (if equipped) Front Work Light Switch (if equipped) Articulation Backup Light Switch (if equipped) Stairwell Light Switch Defrost/Mid Vent Control Switch Cab Air Recirculation Switch Air Conditioner Switch Lower Vent Control Switch Cab Air Temperature Increase Switch Blower Speed Increase Switch Heated Seat Switch (if equipped) Cab Air Temperature Decrease Switch Blower Speed Decrease Switch
<- Go to Section TOC
Section 9005 page 6
TM12406-OPERATION AND TEST MANUAL
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
→NOTE: For more information on 15-button sealed switch module (SSM) (OC4) switch functions, see Sealed Switch Module (SSM) . (Operator’s Manual.) With the ignition ON, activate the following lights: →NOTE: If the machine is not equipped with optional lights, a message will display on the CMU stating: “Option Not Supported.” 1. Dome light 2. Headlights 3. Rotary beacon light 4. Front work lights 5. Articulation lights 6. Turn lights 7. Service brake lights 8. Reverse lights 9. Stairwell light sss: Do all lights operate correctly?
Result: YES:Go to next step in this check. NO:Check fuses for continuity. See Fuse and Relay Specifications . (Group 9015-10.) If fuses are OK, check specific circuit in electrical schematic. See System Functional Schematic and Section Legend . (Group 9015-10.)
Action: Check operation of the windshield wipers and windshield washer.
Windshield Wiper Switch Push the windshield wiper switch until one LED comes ON. sss: Do the windshield wipers activate and delay when parked? Push the windshield wiper switch until two LEDs come ON. sss: Do the windshield wipers activate at low speed? Push the windshield wiper switch until three LEDs come ON. sss: Do the windshield wipers activate at high speed? <- Go to Section TOC
Section 9005 page 7
TM12406-OPERATION AND TEST MANUAL
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Result: YES:Go to next step in this check. NO:If wipers do not operate correctly, check fuses. See Fuse and Relay Specifications . (Group 9015-10.) If fuses are OK, see Windshield Wipers and Washers Circuits Theory of Operation . (Group 9015-15.)
Action:
Windshield Washer Switch Push and hold the windshield washer switch. sss: Does the windshield washer switch LED come ON? sss: Do the windshield washer pump and windshield wipers activate?
Result: YES:Checks complete. NO:If windshield washer does not operate correctly, check fuses. See Fuse and Relay Specifications . (Group 9015-10.) If fuse is OK, see Windshield Wipers and Washers Circuits Theory of Operation . (Group 9015-15.) ( 3 ) Electric Mirrors Checks—If Equipped
Action: Operate each mirror using the mirror switch controls. See Operator Controls . (Operator’s Manual.) sss: Does each mirror move up, down, left, and right?
Result: YES:Check complete. NO:Check 10-amp fuse (F19). See Fuse and Relay Specifications . (Group 9015-10.) If fuse is OK, see Electric Mirror Circuit Theory of Operation . (Group 9015-15.) ( 4 ) Inter-Axle Differential Lock (IDL) and Cross-Axle Differential Lock Check
Action:
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TM12406-OPERATION AND TEST MANUAL
Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Inter-Axle Differential Lock (IDL) Switch Push the inter-axle differential lock (IDL) switch on the SSM. sss: Does IDL switch LED come ON? sss: Does IDL indicator on the CMU come ON? Push the IDL switch on the SSM again. sss: Does IDL switch LED go OFF?
Result: YES:Checks complete. NO: See Inter-Axle Differential Lock (IDL) Does Not Work and see Cross-Axle Differential Lock (CDL) Does Not Work . (Group 9020-15.) See Differential Lock Circuits Theory of Operation . (Group 9015-15.) ( 5 ) Automatic Differential Lock (ADL) Check
Action:
Automatic Differential Lock (ADL) Switch Push the automatic differential lock (ADL) switch on the SSM. sss: Does ADL switch LED come ON? sss: Does ADL indicator on the CMU come ON? Push the ADL switch on the SSM again. sss: Does ADL switch LED go OFF?
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Result: YES:Checks complete. NO: See Inter-Axle Differential Lock (IDL) Does Not Work and see Cross-Axle Differential Lock (CDL) Does Not Work . (Group 9020-15.) See Differential Lock Circuits Theory of Operation . (Group 9015-15.) ( 6 ) Rear View Monitor Check—If Equipped
Action: Make sure battery disconnect switch is ON. Push engine start switch on the 25-button sealed switch module (SSM) once; switched power ON. →NOTE: If security is enabled, the Security screen will appear when the ignition is turned ON. Enter correct personal identification number (PIN) to continue. Observe rear view monitor. sss: Does the rear view monitor display real-time video of objects behind the machine?
Result: YES:Checks complete. NO:Check auto greasing and rear view monitor 5-amp fuse (F26).If fuse is OK, see Rear View Camera Circuit Theory of Operation . (Group 9015-15.)
Operational Checks—Ignition ON, Engine ON Checks ( 1 ) Keyless Ignition Engine Start and Engine Stop Checks
Action: With ignition ON, push and hold engine start switch on 25-button sealed switch module (SSM) OC3 to start engine. sss: Does engine crank and start?
Result: YES:Go to next step in this check. NO:For engine start theory, see Start and Charge Circuits Theory of Operation . (Group 9015-15.) If engine cranks but does not start, see Engine Cranks—Will Not Start . (Group 9010-15.) If engine does not crank, see Engine Will Not Crank . (Group 9010-15.)
Action: Push and immediately release engine stop switch on 25-button SSM (OC3). →NOTE: Depending on operating conditions and engine temperatures, the machine may enter turbo spin-down mode. sss: Does engine shut down? sss: If the machine enters turbo spin-down mode, does the monitor display show a countdown for turbo spin-down? sss: Does engine shut down when countdown reaches 0? <- Go to Section TOC
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Result: YES:Checks complete. NO: See Start and Charge Circuits Theory of Operation . (Group 9015-15.) ( 2 ) Heating and Air Conditioning Systems Check
Action:
15-Button Sealed Switch Module (SSM) (OC4) LEGEND: 1 2 3 4 5 6 7 8 9
Headlight Switch Rotary Beacon Light Switch (if equipped) Heated Mirror Switch (if equipped) Front Work Light Switch (if equipped) Articulation Backup Light Switch (not used) Stairwell Light Switch (not used) Defrost/Mid Vent Control Switch Cab Air Recirculation Switch Air Conditioner Switch
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
10 11 12 13 14 15
Group 10: Operational Checkout Procedure
Lower Vent Control Switch Cab Air Temperature Increase Switch Blower Speed Increase Switch Heated Seat Switch (if equipped) Cab Air Temperature Decrease Switch Blower Speed Decrease Switch
With engine at operating temperature, close cab doors and windows. Push and release blower speed increase switch (12). sss: Does a pop-up appear on the monitor displaying blower speed? sss: Does blower activate? Push and release cab air temperature increase switch (11). sss: Does a pop-up appear on the monitor displaying cab air temperature selection? Push and release blower speed switch until maximum blower speed is active. sss: Does blower speed increase each time switch is pushed? sss: Does the monitor display blower speed indicator? Push and release cab air temperature until maximum heat is selected. sss: Does air from vents become warm? Push and release cab air temperature decrease switch (14) until the coolest temperature is selected. Push and release air conditioner switch (9) (LED on) to enable air conditioning. sss: Does cold air flow from the vents after approximately 2 minutes? Push and release defrost/mid vent control switch once (left LED on). sss: Does air flow toward windshield increase? Push and release defrost/mid vent control switch again (right LED on). sss: Does air flow toward operator increase? Push and release lower vent control switch (10). sss: Does air flow toward cab floor increase? Push and release heated seat switch (13) (if equipped). sss: Do backrest and bottom cushion of seat become warm after approximately 2 minutes?
Result: YES:Checks complete. NO:Check fuses. See Fuse and Relay Specifications . (Group 9015-10.) If fuses are OK, see Air Conditioner and Heater Circuits Theory of Operation . (Group 9015-15.) Also see Air Conditioning System Does Not Operate or see Heater System Does Not Operate . (Group 9031-15.) <- Go to Section TOC
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
( 3 ) Service Brake Checks
Action: CAUTION: Avoid possible injury. Machine will stop abruptly during these checks. Fasten seat belt. Perform the service brake checks in an open area away from other people and machinery. Start engine. →NOTE: To accurately test service brake system performance, reduce amount of transmission retardation to 10%. Reduce percentage of transmission retardation to 10%. See Sealed Switch Module (SSM) . (Operator’s Manual.) Apply the service brakes. Push park brake switch on the 25-button sealed switch module (SSM) (OC3) to release park brake (switch LED off). Push forward gear select switch on the 25-button sealed switch module (SSM) (OC3) to shift transmission into forward gear. Release service brakes and allow machine to travel forward at slow speed. Push brake pedal to stop machine. Release brake pedal. sss: Does brake pedal push easily without binding? sss: Does brake pedal return to the released position so brakes are not dragging? sss: Do brakes stop machine in a reasonable distance without pulling to one side or making noise?
Result: YES:Go to next step in this check. NO: See Poor or No Service Brakes . (Group 9020-15.)
Action: →NOTE: Perform this check in an open area where machine can travel at full speed. Drive machine at full speed. Release accelerator pedal and apply service brakes to stop machine. sss: Do brakes stop machine in a reasonable distance without pulling to one side or making noise?
Result: YES:Checks complete. NO: See Poor or No Service Brakes . (Group 9020-15.) ( 4 ) Accelerator Pedal Check
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Action: CAUTION: Avoid possible serious injury from machine movement. Clear area of all bystanders before performing test. Apply service brakes. Disengage park brake. Push forward gear select switch on the 25-button sealed switch module (SSM) (OC3) to shift transmission into forward gear. Release service brakes. Push accelerator pedal. sss: Does machine speed increase when accelerator pedal is pushed? Release accelerator pedal. sss: Does machine speed decrease when accelerator pedal is released?
Result: YES:Checks complete. NO: See Machine Will Not Move Diagnostic Procedure . (Group 9020-15.) ( 5 ) Transmission Check
Action: CAUTION: Avoid possible serious injury from machine movement. Clear area of all bystanders before performing test. Apply service brakes. Disengage park brake. Push forward gear select switch on the 25-button sealed switch module (SSM) (OC3) to shift transmission into forward gear. Release service brakes. sss: Is forward gear displayed and machine travel forward? Apply service brakes. Push reverse gear select switch on the 25-button sealed switch module (SSM) (OC3) to shift transmission into reverse gear. Release service brakes. sss: Is reverse gear displayed and machine travel in reverse? Apply service brakes. Push neutral selection switch on the 25-button sealed switch module (SSM) (OC3) to shift transmission into neutral. Release service brakes. sss: <- Go to Section TOC
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Is neutral displayed and does machine not move?
Result: YES:Go to next step in this check. NO: See Transmission Will Not Shift to Forward or Reverse . (Group 9020-15.)
Action: Drive machine in forward gear. Press gear range increase switch. sss: Does gear range and machine speed increase? Press gear range decrease switch. sss: Does gear range and machine speed decrease?
Result: YES:Checks complete. NO: See Transmission Will Not Make a Specific Shift . (Group 9020-15.) ( 6 ) Park Brake Check
Action: CAUTION: Avoid possible injury. Machine may move forward when performing this check. Perform this check in an open area away from other people and machinery.
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Park, Drive, Neutral, and Reverse Switches on 25-button Sealed Switch Module (SSM) (OC3) LEGEND: 1 2 3 4
Park Brake Switch Forward Gear Select Switch Neutral Selection Switch Reverse Gear Select Switch
→NOTE: To accurately test the park brake, reduce transmission retardation to 10%. Apply the service brakes. Push forward gear select switch (2) on the 25-button sealed switch module (SSM) (OC3) to shift transmission into forward gear. Release service brakes and run engine at slow idle. sss: Does machine move when engine speed is at slow idle? Slowly increase engine speed to 1200 rpm. →NOTE: Park brake provides adequate braking when a machine is in neutral gear. When in forward gear, the engine will eventually provide enough power to drive through the park brake. sss: Does machine drive through park brake at 1200 rpm?
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Result: YES: See Park Brake Will Not Hold . (Group 9020-15.) NO:Go to next step in this check.
Action: CAUTION: Avoid possible injury. Machine will stop abruptly during this check. Fasten seat belt. Perform this check in an open area away from other people and machinery. Apply the service brakes. Transmission in forward, park brake released. Release service brakes and allow machine to travel forward at slow speed. When machine travel speed reaches approximately 5 km/h (3 mph), push park brake switch to engage park brake. sss: Does park brake engage and machine stop? sss: Does park brake indicator light come ON?
Result: YES:Checks complete. NO: See Park Brake Will Not Hold . (Group 9020-15.) See Park Brake Circuit Theory of Operation . (Group 9015-15.) ( 7 ) Park Brake Functional Check
Action: CAUTION: Prevent possible injury from machine movement. Perform this check away from other people and machinery. Fill dump body with full load of material. Drive machine onto a 15% downhill slope. Apply service brakes. Shift transmission into neutral. Press park brake switch to apply park brake (LED on). Release service brakes. →NOTE: Machine must not move when park brake is applied. sss: Does machine roll forward when park brake is applied?
Result: YES:If machine moves, see Park Brake Will Not Hold . (Group 9020-15.) NO:Checks complete. <- Go to Section TOC
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
( 8 ) Steering Checks
Action: CAUTION: Avoid possible injury. Machine may move forward when performing this check. Perform this check in an open area away from other people and machinery. Park machine in an open area, on a hard, level surface. Shift transmission into neutral. Make sure differential lock is off (deactivated). Release park brake. Release service brakes. Run engine at slow idle. sss: Does steering wheel turn without operator assistance? sss: Does machine turn when steering wheel is stationary?
Result: YES:If steering wheel turns without assistance, see Steering Wheel Turns by Itself . (Group 9025-15.) If machine turns without assistance, see Machine Turns With Steering Valve in Neutral . (Group 9025-15.) NO:Go to next step in this check.
Action: Machine parked on a hard, level surface in an open area. Transmission in neutral. Differential lock off (deactivated). Park brake and service brakes released. Engine running at slow idle. Turn steering wheel fully left, then fully right. sss: Does machine turn in both directions smoothly?
Result: YES:Go to next step in this check. NO:Refer to diagnostic procedure that most closely matches observable symptom: See Slow or No Steering Function . (Group 9025-15.) See Steering Erratic . (Group 9025-15.) See Steering Soft or Spongy . (Group 9025-15.) See Steering Locks Up . (Group 9025-15.) See Steering Wheel Free Play . (Group 9025-15.) See Machine Turns in Opposite Direction As Steering Wheel . (Group 9025-15.)
Action: Run engine at fast idle. Turn steering wheel fully left, then fully right. sss: Does machine turn in both directions smoothly? <- Go to Section TOC
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Result: YES:Checks complete. NO:Refer to diagnostic procedure that most closely matches observable symptom: See Slow or No Steering Function . (Group 9025-15.) See Steering Erratic . (Group 9025-15.) See Steering Soft or Spongy . (Group 9025-15.) See Steering Locks Up . (Group 9025-15.) See Steering Wheel Free Play . (Group 9025-15.) See Machine Turns in Opposite Direction As Steering Wheel . (Group 9025-15.) ( 9 ) Secondary Steering Check
Action: CAUTION: Prevent possible injury and machine damage. This check involves steering machine left and right while machine is moving and engine is off. Perform this check in a open, level area away from other people and machinery. →NOTE: The following conditions will prevent test from starting: Machine is carrying a load. Machine is on an incline of 5% or greater. A diagnostic trouble code is detected on the park brake, service brake, or accelerator pedal sensors. Inter-axle differential lock (IDL) is on. The secondary steering test will simulate a loss of hydraulic pressure from an unexpected engine shutdown. Before performing this test, make sure machine is empty and the differential lock is off. [1] - Park machine in an open area having a hard, level surface. [2] CAUTION: Prevent possible injury and machine damage. A loss of engine power will occur during this test which will result in low hydraulic oil pressure. Be sure to charge service brake accumulators before performing this test. With engine running, press and release service brake pedal until the hydraulic pump strokes and charges service brake accumulators. With engine running, access the SECONDARY STEER menu in the CAN monitor unit (CMU). See CAN Monitor Unit (CMU)—Main Menu—Operation—Secondary Steer Test . (Operator’s Manual.) [3] - Push the SELECT button to enter SECONDARY STEER menu. A pop-up screen will appear listing conditions that must be met for test to continue. A check mark will appear next to each condition indicating that the condition has been met. When all conditions are met, a statement will appear within the pop-up screen stating: PRESS “SELECT” TO START [4] - To activate Secondary Steering Test, push the SELECT button until audible alarm beeps three times. [5] →NOTE: With the secondary steering test active, a 20 km/h (12 mph) speed limit is applied. A pop-up will appear stating: RELEASE PARK BRAKE ACCELERATE TO SPEED LIMIT <- Go to Section TOC
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Apply service brakes, release park brake, and shift transmission to forward gear. [6] →NOTE: Test must be performed with machine travel speed within 18—20 km/h (11—12 mph). →NOTE: If machine travel speed is greater than 20 km/h (12 mph), the system will activate the retarder (based on the SSM requested retardation) until the machine slows to 20 km/h (12 mph), at which point the retarder will deactivate and the transmission will shift into neutral. Release service brakes and accelerate machine to 20 km/h (12 mph) (maximum). [7] →NOTE: The following conditions will cause the test to abort during steps 7—11: Applying the park brake. Applying the service brake. When machine speed reaches 20 km/h (12 mph), a pop-up will appear stating: RELEASE THROTTLE PRESS BRAKE TO ABORT When pop-up appears, release accelerator pedal. [8] - When the accelerator pedal is released, a pop-up will appear stating: ENGINE SHUTDOWN IN PROGRESS [9] - When the machine slows to less than 15 km/h (9 mph), the transmission will automatically shift to neutral, the engine will stop, the audible alarm will beep to notify the operator that the engine has stopped, and a pop-up will appear stating: STEER VEHICLE [10] - Steer the machine to the left and right several times. [11] - When the machine slows to approximately 8 km/h (5 mph), a pop-up will appear stating: COMPLETE! STOP MACHINE AND CYCLE POWER [12] - Using the service brake pedal, bring the machine to a complete stop. [13] - Exit test mode by applying the park brake and pushing engine stop switch to remove ignition power. sss: Does machine turn smoothly in both directions when secondary steering is active? sss: Does machine turn in the intended direction? sss: Does the secondary steering light on the CMU come on and the audible alarm beep when secondary steering is active?
Result: YES:Checks complete. NO: See Steering and Secondary Steering System Operation . (Group 9025-05.) ( 10 ) Descent Control Check
Action:
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
CAUTION: Avoid possible serious injury from machine movement. Clear area of all bystanders before performing test. →NOTE: Descent control does not maintain speed below 10 km/h (6 mph). Push descent control enable switch on SSM (LED on) to enable descent control. When descending a slope, release the accelerator pedal. sss: Does descent control switch LED and descent control indicator illuminate? sss: Is the current machine speed maintained?
Result: YES:Go to next step in this check. NO: See Transmission Retarder Does Not Function . (Group 9020-15.)
Action: When descending a slope, press the brake pedal to slow the machine, then release the brake pedal. sss: Is the new current machine speed maintained?
Result: YES:Checks complete. NO: See Transmission Retarder Does Not Function . (Group 9020-15.)
Action: Push descent control enable switch on SSM (LED off) to disable descent control. sss: Does descent control switch LED and descent control indicator go off?
Result: YES:Checks complete. NO: See Retarder Stays On When Not Requested . (Group 9020-15.) ( 11 ) Dump Body Float and Soft Stop Check
Action: CAUTION: Avoid possible serious injury from machine movement. Clear area of all bystanders before performing test. Area must have an overhead clearance of at least 7.6 m (25 ft) to raise dump body to full height. Do not perform this test within 4 m (13 ft) of high-voltage power lines. Perform this check in a open, level area away from other people and machinery. Park machine so frames are straight. <- Go to Section TOC
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Shift transmission into neutral. Apply park brake.
Dump Body Control Switch Activate soft stop mode by pushing dump body control switch on the 25-button SSM (OC3) until no LEDs are lit. Raise dump body to 100% by pushing and holding the dump body UP switch on 25-button SSM (OC3) or pulling and holding dump body control lever rearward. sss: Does dump body come to a gradual stop at the end of dump body cylinder travel?
Result: YES:Go to next step in this check. NO: See Dump Body Control and Gear Limit Circuits Theory of Operation . (Group 9015-15.) If dump body does not rise, see Dump Body Will Not Rise . (Group 9025-15.)
Action: Lower dump body by pushing and releasing dump body DOWN switch on 25-button SSM or moving dump body control lever fully forward and releasing. Allow dump body to lower fully. sss: Does dump body speed decrease and “float” down to the frame stops when dump body reaches the 2% position?
Result: YES:Checks complete. NO: See Dump Body Control and Gear Limit Circuits Theory of Operation . (Group 9015-15.) ( 12 ) Dump Body Hard Stop Check
Action: CAUTION: Avoid possible serious injury from machine movement. Clear area of all bystanders before performing test. Area must have an overhead clearance of at least 7.6 m (25 ft) to raise dump body to full height. Do not perform this test within 4 m (13 ft) of high-voltage power lines. Perform this check in a open, level area away from other people and machinery. Park machine so frames are straight. Shift transmission into neutral. Apply park brake.
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Dump Body Control Switch Activate hard stop mode by pushing the dump body control switch on the sealed switch module 25-button (SSM) until only right LED is on. This deactivates the soft stop mode. Raise dump body to 100% by pushing and holding the dump body UP switch on SSM or pulling back the dump body control lever (if equipped). sss: Does dump body stop abruptly at the end of dump body cylinder travel?
Result: YES:Go to next step in this check. NO: See Dump Body Control and Gear Limit Circuits Theory of Operation . (Group 9015-15.) If dump body does not rise, see Dump Body Will Not Rise . (Group 9025-15.)
Action: Lower dump body by pushing and releasing dump body DOWN switch on 25-button SSM (OC3) or moving dump body control lever fully forward and releasing. Allow dump body to lower fully. →NOTE: The dump body lower function will latch so it is not necessary to hold the switch down or hold control lever in the forward position (if equipped). sss: Does dump body speed decrease and “float” down to the frame stops when dump body reaches the 2% position?
Result: YES:Checks complete. NO: See Dump Body Control and Gear Limit Circuits Theory of Operation . (Group 9015-15.) ( 13 ) Driveline Assist Check
Action: CAUTION: Avoid possible serious injury from machine movement. Perform this check in a open, level area away from other people and machinery. Area must have an overhead clearance of at least 7.6 m (25 ft) to raise dump body to full height. Do not perform this test within 4 m (13 ft) of high-voltage power lines. Perform this check in a open, level area away from other people and machinery. Park machine so frames are straight. <- Go to Section TOC
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Dump Body Control Switch Activate driveline assist mode by pushing the dump body control switch on the 25-button SSM (OC3) until the left LED is on. →NOTE: If the left and right LEDs are lit, both hard stop and driveline assist are enabled. Apply service brakes, release park brake, and shift transmission into reverse. →NOTE: Driveline assist will not function if vehicle ground speed is detected. Once the machine has stopped moving, driveline assist will activate. Raise dump body by momentarily pushing the dump body UP switch on 25-button SSM (OC3) or pulling back the dump body control lever. →NOTE: When the dump body starts to rise, engine speed control is taken over by the system. The accelerator pedal will not function until dump body is lowered and machine is in forward gear. sss: Do the service brakes automatically latch and transmission go to neutral? sss: Does engine speed increase to fast idle (2250 rpm)? →NOTE: The dump body raise function will latch, so it is not necessary to hold the dump body UP switch or dump body control lever. sss: Does dump body rise fully?
Result: YES:Go to next step in this check. NO: See Dump Body Control and Gear Limit Circuits Theory of Operation . (Group 9015-15.)
Action: Lower dump body by pushing dump body DOWN switch on 25-button SSM (OC3) or moving dump body control lever fully forward (if equipped). →NOTE: The dump body lower function will latch so it is not necessary to hold the switch down or hold control lever in the forward position. Shift transmission into a forward gear and accelerate forward while dump body is lowering. <- Go to Section TOC
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
→NOTE: The transmission will shift into forward gear while the dump body is lowering or fully lowered. sss: Do service brakes automatically unlatch as machine moves forward? sss: Does dump body lower fully?
Result: YES:Checks complete. NO: See Dump Body Control and Gear Limit Circuits Theory of Operation . (Group 9015-15.) ( 14 ) On Board Weighing (OBW) Load Lights Checks
Action: Dump body must be empty before performing this check. Cycle ignition OFF, then back ON. sss: Do all OBW load lights flash when ignition is turned ON? sss: After approximately 30 seconds, do the green and red lights go off and does the yellow light continue to flash?
Result: YES:Go to next step in this check. NO: See Onboard Weighing (OBW) Controller Circuit Theory of Operation . (Group 9015-15.)
Action: CAUTION: Avoid possible serious injury from machine movement. Clear area of all bystanders before performing test. Area must have an overhead clearance of at least 7.6 m (25 ft) to raise dump body to full height. Do not perform this test within 4 m (13 ft) of high-voltage power lines. Start engine. Raise dump body above the 50% position. Lower dump body fully. sss: Do all OBW load lights flash after dump body is lowered? sss: After approximately 30 seconds, do the green and red lights go off and does the yellow light continue to flash?
Result: YES:Go to next step in this check. NO: See Onboard Weighing (OBW) Controller Circuit Theory of Operation . (Group 9015-15.)
Action: Apply service brakes to release park brake. <- Go to Section TOC
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Section 9005 - OPERATIONAL CHECKOUT PROCEDURE
Group 10: Operational Checkout Procedure
Shift transmission into drive. Accelerate machine until travel speed is more than 5 km/h (3 mph). sss: Does the yellow load light go off (all load lights off) when travel speed reaches approximately 5 km/h (3 mph)?
Result: YES:Checks complete. NO: See Onboard Weighing (OBW) Controller Circuit Theory of Operation . (Group 9015-15.) ( 15 ) Engine Speed Check
Action: →NOTE: Verify the engine is not in Service Regeneration while performing the following checks. With engine and transmission at normal operating temperature, run engine at slow idle. Record rpm. sss: Is engine speed 900 rpm? Increase engine speed to fast idle. Record rpm. sss: Is engine speed 2250 rpm?
Result: YES:Checks complete. NO:Check engine speed control circuits and components. See Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) See Engine Idles Poorly . (Group 9010-15.) ( 16 ) Exhaust Smoke Check
Action: With engine at normal operating temperature, operate machine under full load at fast engine speed. Observe exhaust. No smoke is normal. White or gray smoke is caused by coolant or raw, unburned fuel passing into the exhaust stream. Blue smoke is caused by burning engine lubricating oil. sss: Is engine exhaust normal?
Result: YES:Checks complete. NO:Diagnose problem according to color of smoke.For white smoke, see Engine Emits Excessive White Exhaust Smoke . (Group 9010-15.) For black or gray smoke, see Engine Emits Excessive Black or Gray Exhaust Smoke . (Group 9010-15.) ( 17 ) Cycle Times Check
Action: Warm hydraulic oil. See Hydraulic System Warmup Procedure . (Group 9025-25.) Use a stopwatch to record cycle times. <- Go to Section TOC
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TM12406-OPERATION AND TEST MANUAL
ENGINE
(g) by Belgreen v2.0
sss: Are cycle times to specification? Dump Body Cycle Time Specifications Item
Measurement
Specification
Hydraulic Oil
Temperature
45—55° C 110—130° F
Engine
Speed
2250 rpm
Dump Body Raise—Cycle Time
Cycle Time
12—14 sec.
Dump Body Power Down—Cycle Time
Cycle Time
7.5—9.5 sec.
Steering Cycle Time Specifications Item
Measurement
Specification
Engine
Speed
2250 rpm
Steering Wheel Stop-to-Stop
Cycle Time
3.5—5.5 sec.
Result: YES:Checks complete. NO: See All Hydraulic Functions Slow . Group (9025-15.)
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Section 9010 page 27
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TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Section 9010 - ENGINE Table of contents Group 05 - Theory of Operation ............................................................................................................. 1 John Deere Engine Theory of Operation ............................................................................................... 1 Cold Start Aids Theory of Operation—If Equipped ................................................................................ 2 Fast Fill Fuel System Theory of Operation—If Equipped ....................................................................... 4 Group 15 - Diagnostic Information ........................................................................................................ 6 John Deere Engine Diagnostic Information ........................................................................................... 6 Engine Cooling System Component Location ....................................................................................... 7 Engine Fuel System Component Location ............................................................................................ 9 Engine Intake and Exhaust Component Location ............................................................................... 11 Engine Cranks—Will Not Start Diagnostic Procedure .......................................................................... 13 Engine Misfires/Runs Irregularly Diagnostic Procedure ....................................................................... 15 Engine Does Not Develop Full Power Diagnostic Procedure ............................................................... 16 Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure ................................................ 17 Engine Emits Excessive Black or Gray Exhaust Smoke Diagnostic Procedure .................................... 17 Engine Will Not Crank Diagnostic Procedure ...................................................................................... 19 Engine Idles Poorly Diagnostic Procedure ........................................................................................... 21 Abnormal Engine Noise Diagnostic Procedure .................................................................................... 22 Low Pressure Fuel System Check Procedure ...................................................................................... 23 High Pressure Fuel System Check Diagnostic Procedure .................................................................... 23 Excessive Fuel Consumption Diagnostic Procedure ............................................................................ 24 Fuel in Oil Diagnostic Procedure ......................................................................................................... 25 Fast Fill Fuel System Underfill—If Equipped Diagnostic Procedure ..................................................... 26 Fast Fill Fuel System Overfill—If Equipped Diagnostic Procedure ....................................................... 27 Fast Fill Fuel System Nozzle Leaks at Receiver—If Equipped Diagnostic Procedure ........................... 27 Active or Passive Regeneration Does Not Complete Cycle Diagnostic Procedure .............................. 29 Group 20 - Adjustments ........................................................................................................................ 31 Service Filter Cleaning ........................................................................................................................ 31 John Deere Engine Adjustments ......................................................................................................... 31 Group 25 - Tests ..................................................................................................................................... 32 John Deere Engine Tests ..................................................................................................................... 32 Fluid Sampling Procedure ................................................................................................................... 33 Engine Slow and Fast Idle Speed Check ............................................................................................. 37
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TM12406-OPERATION AND TEST MANUAL
Section 9010 - ENGINE
Group 05: Theory of Operation
Group 05 - Theory of Operation John Deere Engine Theory of Operation This machine uses a John Deere PowerTech ™ 13.5 liter diesel engine. The engine model is 6135HDW05. To identify the model of engine, see Engine Serial Number Plate Information . (CTM104919). For theory of operation on John Deere PowerTech ™ engines, model 6135HDW05 not contained in this group, see the following: See General Engine Operation . (CTM104919.) See Lubrication System Operation . (CTM104919.) See Cooling System Operation . (CTM104919.) See Fuel System Operation . (CTM104919.) See Air Intake and Exhaust System Operation . (CTM104919.) See Aftertreatment System Operation . (CTM104919). See Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) For additional information, see 6135 PowerTech™ OEM Diesel Engines (Interim Tier 4/Stage III B platform) . (CTM104919.)
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Section 9010 page 1
TM12406-OPERATION AND TEST MANUAL
Section 9010 - ENGINE
Group 05: Theory of Operation
Cold Start Aids Theory of Operation—If Equipped
Cold Start Aids (Stage II Engine Shown) LEGEND: 1 2 3 4 5 6 7 8 9 10
Diesel Fired Coolant Heater Fuel Supply Line Diesel Fired Coolant Heater Exhaust Pipe Diesel Fired Coolant Heater Coolant Line Ether Start Nozzle Ether Start Canister 220V Engine Block Heater Fuel Filter Heater (auxiliary fuel filter and water separator) Diesel Fired Coolant Heater Coolant Supply Diesel Fired Coolant Heater Diesel Fired Coolant Heater Intake
Ether Start Ether injection helps to start the engine in cold weather by injecting a specific amount of ether into the intake manifold. Ether requires a lower temperature to ignite than diesel fuel; therefore, inside the combustion chamber the ether ignites first, heating the diesel fuel and aiding combustion. For more information on cold start aid system, see Cold Start Aid Circuits Theory of Operation . (Group 9015-15.)
Fuel Filter Heater The fuel filter heater is a resistor element located inside the auxiliary fuel filter and water separator. This heater prevents fuel filters from clogging due to fuel gelling. For more information on the fuel filter heater, see Start and Charge Circuits Theory of Operation and see Cold Start Circuits Theory of Operation . (Group 9015-15.)
Engine Block Heater The engine block heater is installed into the cooling jacket of the engine block. The heated coolant warms the engine block and the air in the combustion chamber. This warm air aids in cold weather combustion until the engine reaches operating temperature. Ensure the correct supply voltage is provided to the engine block heater, see Engine Block Heater—If Equipped . (Operator’s Manual.)
Diesel Fired Coolant Heater The coolant heater system allows for rapid heating of the machine′s coolant. The heater pumps coolant from the engine, heats <- Go to Section TOC
Section 9010 page 2
TM12406-OPERATION AND TEST MANUAL
Section 9010 - ENGINE
Group 05: Theory of Operation
it, and returns it to the engine. A temperature regulating switch in the unit regulates the coolant temperature between a low of 68°C (154°F) and a high of 85°C (185°F) by automatically cycling the heater.
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Section 9010 page 3
TM12406-OPERATION AND TEST MANUAL
Section 9010 - ENGINE
Group 05: Theory of Operation
Fast Fill Fuel System Theory of Operation—If Equipped
Fast Fill Theory of Operation LEGEND: 1 2 3 4 5 6 7 8 9 10 11
Standard Fuel Cap Fuel Tank Inlet Receiver Inlet Shutoff Valve Incoming Fuel Signal Line Bleed Fuel Fuel Level Control/Float Assembly Breather Valve Escaping Gases Breather Filter
The fast fill fuel system is a system that allows for rapid refueling of the machine. The fast fill fuel system is designed to fill at rates up to 570 L/m (150 gpm) depending on receiver size, hose length, and fueling pump capacity. The fast fill fuel system consists of an inlet receiver (3), inlet shutoff valve (4), signal line (6), fuel level control/float assembly (8), and a poppet vent. The receiver may be mounted directly to the fuel tank (2), or remote mounted for easier fueling. The inlet shutoff valve is usually located lower in the tank to reduce foaming during refueling. The fuel level control/float assembly and poppet vent are located at the top of the fuel tank. The length of the fuel level control/float assembly determines the shutoff level in the fuel tank. The poppet vent is located on top of the fuel level control/float assembly and is external to the tank. The poppet vents escaping gases from the fuel tank as fuel is added. The signal line is a flexible braided stainless steel line that connects the inlet shutoff valve to the fuel level control/float assembly. When the fuel tank fuel level is low, fuel enters the fuel tank through the inlet receiver and inlet shutoff valve. A small amount of the incoming fuel (5) is bled off to the signal line from the inlet shutoff valve and sent up to the fuel level control/float assembly. The bleed fuel (7) then drains into the fuel tank from the float assembly. The poppet vent allows vapors to escape from the displacement of the incoming fuel. The vent is designed to keep the tank pressure under 3.5 kPa (0.5 psi). This prevents the fuel tank from building too much pressure during fueling. <- Go to Section TOC
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Section 9010 - ENGINE
Group 15: Diagnostic Information
As the fuel tank fills, the float rises in the float assembly. When the tank is full, the float assembly shuts off the bleed flow from the signal line. This causes the signal line to pressurize from the pressure of the incoming fuel. When the signal line pressurizes, the inlet shutoff valve closes and no additional fuel can be added.
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TM12406-OPERATION AND TEST MANUAL
Section 9010 - ENGINE
Group 15: Diagnostic Information
Group 15 - Diagnostic Information John Deere Engine Diagnostic Information This machine uses a John Deere PowerTech ™ 13.5 liter diesel engine. The engine model is 6135HDW05. To identify the model of engine, see Engine Serial Number Plate Information . (CTM104919). For diagnostic information on John Deere PowerTech ™ engines, model 6135HDW05 not contained in this group, see the following: Abnormal Engine Noise . (CTM104919). Coolant in Oil or Oil in Coolant . (CTM104919). Mechanical Compression Check . (CTM104919). For additional information, see 6135 PowerTech™ OEM Diesel Engines (Interim Tier 4/Stage III B platform) . (CTM104919.)
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Engine Cooling System Component Location
Engine Cooling System Component Location LEGEND: 1 2 3 4
Surge Tank Surge Tank Overflow Hose Precooler Hose-to-Surge Tank Hose Surge Tank Hose
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Section 9010 - ENGINE
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Group 15: Diagnostic Information
Surge Tank-to-Thermostat Housing Hose Charge Air Precooler-to-Engine Block Hose Surge Tank Hose-to-Charge Air Precooler Hose Surge Tank Hose-to-Left Radiator Hose Surge Tank Hose-to-Right Radiator Hose Left Radiator Right Radiator Coolant Pump Surge Tank-to-Coolant Pump Hose Charge Air Precooler Charge Air Precooler-to-Thermal Bypass Valve Hose Thermal Bypass Valve Thermal Bypass-to-Lower Radiator Tube Hose Drain Hose Drain Valve Upper Radiator Tube-to-Left Radiator Hose Lower Radiator Tube-to-Left Radiator Hose Upper Radiator Tube Lower Radiator Tube Upper Radiator Tube-to-Thermostat Housing Hose Upper Radiator Tube-to-Right Radiator Hose Coolant Pump-to-Lower Radiator Tube Hose Lower Radiator Tube-to-Right Radiator Hose Thermostat Housing
For additional information see Component Location Diagrams . (CTM104919.)
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Engine Fuel System Component Location
Fuel System Component Location LEGEND: 1 2 3 4 <- Go to Section TOC
Fuel Tank Fuel Tank-to-Fuel Filter Header Line Primer Primary Fuel Filter Drain Line Section 9010 page 9
TM12406-OPERATION AND TEST MANUAL
Section 9010 - ENGINE
5 6 7 8 9 10 11 12 13 14 15 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 B37 B5600 R10
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Group 15: Diagnostic Information
Primary Fuel Filter Secondary Fuel Filter Severe Duty Fuel Filter (if equipped) Fuel Filter Header Fuel Transfer Pump Fuel Transfer Pump-to-High Pressure Fuel Pump Line Fuel Filter Header-to-Fuel Cooler Line Cylinder Head-to-Fuel Filter Header Return Line Fuel Cooler-to-Fuel Tank Line Fuel Filter Header-to-Fuel Cooler Line Severe Duty Fuel Filter Drain Line (if equipped) Severe Duty Fuel Filter-to-Fuel Filter Header Line (if equipped) Fuel Tank-to-Severe Duty Fuel Filter Line (if equipped) Fuel Filter Header-to-Fuel Dosing Pump Return Line Fuel Filter Header-to-Fuel Dosing Pump Supply Line Fuel Cooler Fast Fill Fuel Tank Vent High Pressure Fuel Pump Fuel Dosing Unit-to-Fuel Dosing Injector Line Fuel Dosing Pump-to-Fuel Dosing Unit Line Fuel Dosing Unit Fuel Dosing Pump Fuel Dosing Injector High Pressure Fuel Pump-to-Cylinder Head Line Severe Duty Configuration Standard Configuration Fuel Level Sensor Water-in-Fuel (WIF) Sensor Fuel Filter Heater (if equipped)
Section 9010 page 10
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Group 15: Diagnostic Information
Engine Intake and Exhaust Component Location
Intake and Exhaust System Component Location LEGEND: 1 2 3 4 <- Go to Section TOC
Variable Geometry Turbocharger Muffler Diverter Valve Fixed Geometry Turbocharger Section 9010 page 11
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Section 9010 - ENGINE
5 6 7 8 9 10
Group 15: Diagnostic Information
Exhaust Gas Recirculation (EGR) Valve Air Throttle Actuator Charge Air Cooler Air Cleaner Assembly Charge Air Precooler Dump Body Interface
For additional information see Component Location Diagrams . (CTM104919.)
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Engine Cranks—Will Not Start 66
Engine Cranks—Will Not Start Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are DTCs present?
Result: YES:Correct malfunction causing DTC(s). NO:Go to Fuel Supply Check. ( 2 ) Fuel Supply Check
Action: Check quality of fuel, see Fluid Sampling Procedure . (Group 9010-25.) Is fuel quality acceptable?
Result: YES:Go to Fuel Line Check. NO:Replace fuel. ( 3 ) Fuel Line Check
Action: Check fuel supply lines, see Engine Fuel System Component Location . (Group 9010-15.) Are fuel lines kinked, collapsed, or broken?
Result: YES:Replace fuel lines. NO:Go to Air Intake Restriction Check. ( 4 ) Air Intake Restriction Check
Action: Check precleaner and filter inlet for obstructions. Check engine air intake system, see Service Engine Air Intake System . (Operator′s Manual.) Is the air intake system restricted?
Result: YES:Clean precleaner and clean or replace air filter elements. NO:Go to Exhaust Restriction Check. ( 5 ) Exhaust Restriction Check
Action: Check exhaust for restriction. Is the exhaust restricted?
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Result: YES:Remove exhaust restriction, see Service Filter Cleaning . (Group 9010-20.) NO:Go to Crankcase Pressure (Blow-By) Check. ( 6 ) Crankcase Pressure (Blow-By) Check
Action: Check crankcase pressures and compression. See Crankcase Pressure (Blow-By) Test . (CTM104919.) Are crankcase pressures and cylinder compression within specification?
Result: YES:For further diagnostic information, see Engine Cranks and Will Not Start . (CTM104919.) NO:For engine repair information, see Repair and Adjustments . (CTM104919.)
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Engine Misfires/Runs Irregularly 66
Engine Misfires/Runs Irregularly Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for diagnostic trouble codes (DTC). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are DTC(s) present?
Result: YES:Correct malfunction causing DTC(s). NO:Go to Fuel Supply Check. ( 2 ) Fuel Supply Check
Action: Check quality of fuel, see Fluid Sampling Procedure . (Group 9010-25.) Is fuel quality acceptable?
Result: YES:Go to Fuel Line Check. NO:Replace fuel. ( 3 ) Fuel Line Check
Action: Check fuel supply lines, see Engine Fuel System Component Location . (Group 9010-15.) Are fuel lines kinked, collapsed, or broken?
Result: YES:Replace fuel lines. NO:Go to Crankcase Pressure (Blow-By) Check. ( 4 ) Crankcase Pressure (Blow-By) Check
Action: Check crankcase pressures and compression. See Crankcase Pressure (Blow-By) Test . (CTM104919.) Are crankcase pressures and cylinder compression within specification?
Result: YES:For further diagnostic information, see Engine Misfires or Runs Irregularly . (CTM104919.) NO:For engine repair information, see Repair and Adjustments . (CTM104919.)
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Engine Does Not Develop Full Power 66
Engine Does Not Develop Full Power Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are DTCs present?
Result: YES:Correct malfunction causing DTC(s). NO:Go to Fuel Supply Check. ( 2 ) Fuel Supply Check
Action: Check quality of fuel, see Fluid Sampling Procedure . (Group 9010-25.) Is fuel quality acceptable?
Result: YES:Go to Fuel Line Check. NO:Replace fuel. ( 3 ) Fuel Line Check
Action: Check fuel supply lines, see Engine Fuel System Component Location . (Group 9010-15.) Are fuel lines kinked, collapsed, or broken?
Result: YES:Replace fuel lines. NO:Go to Air Intake Restriction Check. ( 4 ) Air Intake Restriction Check
Action: Check precleaner and filter inlet for obstructions. Check engine air intake system, see Service Engine Air Intake System . (Operator′s Manual.) Is the air intake system restricted?
Result: YES:Clean precleaner and clean or replace air filter elements. NO:Go to Exhaust Restriction Check. ( 5 ) Exhaust Restriction Check
Action: Check exhaust for restriction. Is the exhaust restricted?
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Result: YES:Remove exhaust restriction, see Service Filter Cleaning . (Group 9010-20.) NO:Go to Crankcase Pressure (Blow-By) Check. ( 6 ) Crankcase Pressure (Blow-By) Check
Action: Check crankcase pressures and compression. See Crankcase Pressure (Blow-By) Test . (CTM104919.) Are crankcase pressures and cylinder compression within specification?
Result: YES:For further diagnostic information, see Engine Does Not Develop Full Power . (CTM104919.) NO:For engine repair information, see Repair and Adjustments . (CTM104919.) Engine Emits Excessive White Exhaust Smoke 66
Engine Emits Excessive White Exhaust Smoke Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are DTCs present?
Result: YES:Correct malfunction causing DTC(s). NO:Go to Fluids Check. ( 2 ) Fluids Check
Action: Check condition of coolant and oil, see Fluid Sampling Procedure . (Group 9010-25.) Are fluid qualities acceptable?
Result: YES:Go to Cold Start Aid Check. NO:Find and correct cause of poor quality fluids, see Coolant in Oil or Oil in Coolant . (CTM104919.) ( 3 ) Cold Start Aid Check
Action: Check cold start aid operation, see Cold Start Aids Theory of Operation—If Equipped . (Group 9010-05.) Is the cold start aid operating properly?
Result: YES:For further diagnostic information, see Engine Emits Excessive White Exhaust Smoke . (CTM104919.) NO:Repair or replace cold start aid as required. Engine Emits Excessive Black or Gray Exhaust Smoke 130
Engine Emits Excessive Black or Gray Exhaust Smoke Diagnostic <- Go to Section TOC
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Procedure ( 1 ) Black Smoke Check
Action: Is black or grey smoke only for a short period of time after a Service Regeneration is performed or a new DPF is installed?
Result: YES:This is normal operation. NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are DTCs present?
Result: YES:Correct malfunction causing DTC(s). NO:Go to Fuel Supply Check. ( 3 ) Fuel Supply Check
Action: Check quality of fuel, see Fluid Sampling Procedure . (Group 9010-25.) Is fuel quality acceptable?
Result: YES:For further diagnostic information, see Engine Emits Excessive Black or Gray Exhaust Smoke . (CTM104919.) NO:Replace fuel.
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Engine Will Not Crank 66
Engine Will Not Crank Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are DTCs present?
Result: YES:Correct malfunction causing DTC(s). NO:Go to Battery Condition Check. ( 2 ) Battery Condition Check
Action: Check batteries. See Check Batteries, Clean and Tighten Terminals . (Operator′s Manual.) Are batteries fully charged?
Result: YES:Go to Battery Cable Check. NO:Charge batteries. See Using Battery Charger . (Operator′s Manual.) ( 3 ) Battery Cable Check
Action: Check battery connections. See Check Batteries, Clean and Tighten Terminals . (Operator′s Manual.) Are battery cable clamps tight on battery and clean?
Result: YES:Go to General Electrical Check. NO:Clean battery cable clamps and tighten. ( 4 ) General Electrical Check
Action: Check electrical devices (lights, radio, etc.). Do other electrical devices work properly?
Result: YES:Go to Starter Check. NO:Check machine ground cables. ( 5 ) Starter Check
Action: Check voltage at starter. See Start and Charge Circuits Theory of Operation . (Group 9015-15.) Is the voltage at the starter the same as the voltage at the batteries when attempting to start engine?
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Result: YES:Remove starter for inspection and testing. NO: See Engine Will Not Crank . (CTM104919.)
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Engine Idles Poorly 66
Engine Idles Poorly Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are DTCs present?
Result: YES:Correct malfunction causing DTC(s). NO:Go to Fuel Supply Check. ( 2 ) Fuel Supply Check
Action: Check quality of fuel, see Fluid Sampling Procedure . (Group 9010-25.) Is fuel quality acceptable?
Result: YES:Go to Fuel Line Check. NO:Replace fuel. ( 3 ) Fuel Line Check
Action: Check fuel supply lines, see Engine Fuel System Component Location . (Group 9010-15.) Are fuel lines kinked, collapsed, or broken?
Result: YES:Replace fuel lines. NO:Go to Air Intake Restriction Check. ( 4 ) Air Intake Restriction Check
Action: Check precleaner and filter inlet for obstructions. Check engine air intake system, see Service Engine Air Intake System . (Operator′s Manual.) Is the air intake system restricted?
Result: YES:Clean precleaner and clean or replace air filter elements. NO:Go to Exhaust Restriction Check. ( 5 ) Exhaust Restriction Check
Action: Check exhaust for restriction. Is the exhaust restricted?
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Result: YES:Remove exhaust restriction, see Service Filter Cleaning . (Group 9010-20.) NO:For further diagnostic information, see Diagnostics . (CTM104919.) Abnormal Engine Noise 66
Abnormal Engine Noise Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are DTCs present?
Result: YES:Correct malfunction causing DTC(s). NO:Go to Oil Level Check. ( 2 ) Oil Level Check
Action: Check engine oil level. See Checking Engine Oil Level . (Operator′s Manual.) Is engine oil at proper fill level?
Result: YES:For more diagnostic information, see Abnormal Engine Noise . (CTM104919.) NO:Drain or fill oil to proper level.
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Low Pressure Fuel System Check 66
Low Pressure Fuel System Check Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are DTCs present?
Result: YES:Correct malfunction causing DTC(s). NO:Go to Fuel Supply Check. ( 2 ) Fuel Supply Check
Action: Check quality of fuel, see Fluid Sampling Procedure . (Group 9010-25.) Is fuel quality acceptable?
Result: YES:Go to Fuel Line Check. NO:Replace fuel. ( 3 ) Fuel Line Check
Action: Check fuel supply lines, see Engine Fuel System Component Location . (Group 9010-15.) Are fuel lines kinked, collapsed, or broken?
Result: YES:Replace fuel lines. NO:Go to Replace Fuel Filters. ( 4 ) Replace Fuel Filters
Action: Replace fuel filters, see Replace Primary Fuel Filter and Water Separator , Replace Secondary Fuel Filter , and Auxiliary Fuel Filter and Water Separator—If Equipped . (Operator’s Manual.) Is low fuel pressure fuel system operating correctly?
Result: YES:Return machine to service. NO:For further diagnostic information, see Fuel Supply System Check . (CTM370.) High Pressure Fuel System Check 66
High Pressure Fuel System Check Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic <- Go to Section TOC
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Application . (Group 9015-20.) Are DTCs present?
Result: YES:Correct malfunction causing DTC(s). NO:Go to Low Pressure Fuel System Check. ( 2 ) Low Pressure Fuel System Check
Action: Perform Low Pressure Fuel System Check, see Low Pressure Fuel System Check . (Group 9010-15.) Is fuel system high pressure restored?
Result: YES:Return machine to service. NO:For further diagnostic information, see Fuel Supply System Check . (CTM370.) Excessive Fuel Consumption 66
Excessive Fuel Consumption Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are DTCs present?
Result: YES:Correct malfunction causing DTC(s). NO:Go to Fuel Supply Check. ( 2 ) Fuel Supply Check
Action: Check quality of fuel, see Fluid Sampling Procedure . (Group 9010-25.) Is fuel quality acceptable?
Result: YES:Go to Fuel Line Check. NO:Replace fuel. ( 3 ) Fuel Line Check
Action: Check fuel supply lines, see Engine Fuel System Component Location . (Group 9010-15.) Are fuel lines kinked, collapsed, or broken?
Result: YES:Replace fuel lines. NO:Go to Fuel Tank Check. ( 4 ) Fuel Tank Check <- Go to Section TOC
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Action: Check fuel tank. See Engine Fuel System Component Location . (Group 9010-15.) Is fuel tank damaged or leaking?
Result: YES:Repair or replace fuel tank. See Fuel Tank Remove and Install . (Group 0560.) NO: See Excessive Fuel Consumption . (CTM370.) Fuel in Oil 66
Fuel in Oil Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are DTCs present?
Result: YES:Correct malfunction causing DTC(s). NO:Go to Oil Contamination Check. ( 2 ) Oil Contamination Check
Action: Test oil for fuel contamination. See Fluid Sampling Procedure . (Group 9010-25.) Is engine oil contaminated with fuel?
Result: YES: See Fuel in Oil . (CTM370.) NO:Checks complete.
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Group 15: Diagnostic Information
Fast Fill Fuel System Underfill—If Equipped 268
Fuel tank is underfilled when using fast fill fuel system.
Fast Fill Fuel System Underfill—If Equipped Diagnostic Procedure ( 1 ) Machine Angle Check
Action: Move machine to a flat, level surface. Fill fuel tank using fast fill fuel system. Is fuel tank underfilled?
Result: YES:Go to Filler Valve Check. NO:Checks complete. ( 2 ) Filler Valve Check
Action: Check filler valve on nozzle for excessive wear. See Fast Fill Fuel System Theory of Operation—If Equipped . (Group 9010-05.) Is filler valve worn?
Result: YES:Rebuild or replace nozzle. NO:Go to Inlet Shutoff Valve Screen Check. ( 3 ) Inlet Shutoff Valve Screen Check
Action: Remove inlet shutoff valve. See Fast Fill Fuel System Disassemble and Assemble—If Equipped . (Group 0560.) Inspect inlet shutoff valve screen for debris. Is any debris present on screen?
Result: YES:Clean or replace screen. NO:Go to Signal Line Check. ( 4 ) Signal Line Check
Action: Remove signal line. See Fast Fill Fuel System Disassemble and Assemble—If Equipped . (Group 0560.) Check for debris or restrictions in signal line. Is signal line restricted?
Result: YES:Clean and install signal line. NO:Go to Fuel Level Control/Float Check. ( 5 ) Fuel Level Control/Float Check
Action: Remove fuel level control valve. See Fast Fill Fuel System Disassemble and Assemble—If Equipped . (Group 0560.) <- Go to Section TOC
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Section 9010 - ENGINE
Group 15: Diagnostic Information
Check to see if correct fuel level control valve is installed. Is correct valve installed?
Result: YES:Checks complete. NO:Replace fuel level control valve. Fast Fill Fuel System Overfill—If Equipped 268
Fuel tank is overfilled when using fast fill fuel system.
Fast Fill Fuel System Overfill—If Equipped Diagnostic Procedure ( 1 ) Machine Angle Check
Action: Move machine to a flat, level surface. Fill fuel tank using fast fill fuel system. Is fuel tank overfilled?
Result: YES:Go to Signal Line Leak Check. NO:Checks complete. ( 2 ) Signal Line Leak Check
Action: Remove signal line. See Fast Fill Fuel System Disassemble and Assemble—If Equipped . (Group 0560.) Check signal line and fittings for leaks. Are fittings or signal line leaking?
Result: YES:Replace signal line and fittings. NO:Checks complete. Fast Fill Fuel System Nozzle Leaks at Receiver—If Equipped 268
Fast fill fuel system leaks at fuel inlet receiver.
Fast Fill Fuel System Nozzle Leaks at Receiver—If Equipped Diagnostic Procedure ( 1 ) Filler Valve Check
Action: Check filler valve on nozzle for excessive wear. See Fast Fill Fuel System Theory of Operation—If Equipped . (Group 9010-05.) Is filler valve worn?
Result: YES:Rebuild or replace nozzle. NO:Go to Inlet Receiver Check. ( 2 ) Inlet Receiver Check
Action: Check inlet receiver for excessive wear. See Engine Fuel System Component Location . (Group 9010-15.) <- Go to Section TOC
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Group 15: Diagnostic Information
Is receiver worn?
Result: YES:Replace inlet receiver. See Fast Fill Fuel System Disassemble and Assemble—If Equipped . (Group 0560.) NO:Checks complete.
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Group 15: Diagnostic Information
Active or Passive Regeneration Does Not Complete Cycle 268
DPF soot level is most severe high.
Active or Passive Regeneration Does Not Complete Cycle Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are DTCs present?
Result: YES:Correct malfunction causing DTC(s). NO:Go to Auto Cleaning Enable Check. See CAN Monitor Unit (CMU)—Exhaust Filter . (Group 9015-16.) ( 2 ) Auto Cleaning Enable Check
Action: Enable auto filter cleaning in the CAN monitor unit (CMU). See CAN Monitor Unit (CMU)—Main Menu—Exhaust Filter—Auto Cleaning . (Operator’s Manual.) Is a filter cleaning initiated?
Result: YES:Checks complete. NO:Go to Parked Cleaning Check. See CAN Monitor Unit (CMU)—Exhaust Filter . (Group 9015-16.) ( 3 ) Parked Cleaning Check
Action: Perform parked cleaning in the CAN monitor unit (CMU). See CAN Monitor Unit (CMU)—Main Menu—Exhaust Filter—Parked Cleaning . (Operator’s Manual.) Is a filter cleaning initiated?
Result: YES:Checks complete. NO:Go to Service Cleaning Check. ( 4 ) Service Cleaning Check
Action: Perform service cleaning in the CAN monitor unit (CMU). See CAN Monitor Unit (CMU)—Exhaust Filter . (Group 9015-16.) Is a filter cleaning initiated?
Result: YES:Checks complete. NO:Update ECU or CCU software version. ( 5 ) Update ECU or CCU Software Version Check
Action: Program ECU and CCU. <- Go to Section TOC
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Group 20: Adjustments
Is a filter cleaning initiated?
Result: YES:Checks complete. NO:Go to Air Throttle Check. ( 6 ) Air Throttle Tolerance Check
Action: Measure the flap gap on right and left side of the air throttle valve (2). LEGEND: 1 2 3 4
Thickness Gauge Air Throttle Valve Left Side Flap Right Side Flap
Air Throttle Tolerance Check Measurement Process : Push the flap into closed position. Measure the right side gap through thickness gauge (1). Item
Measurement
Specification
Gap (maximum)
0.6 mm
Air Throttle Flap Gap Right side
0.023 in. Left side
Gap (maximum)
0.1 mm 0.004 in.
Is 0.6 mm thickness gauge is going through the right side gap ?
Result: YES:Replace the air throttle valve and gasket. See Air Throttle and EGR Mixer Housing — Installation and Air Throttle and EGR Mixer Housing — Removal (CTM104919). NO:Checks complete.
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Section 9010 - ENGINE
Group 25: Tests
Group 20 - Adjustments Service Filter Cleaning CAUTION: Servicing machine during a service filter cleaning can result in serious personal injury. Avoid exposure and skin contact with hot gases and components. During a service filter cleaning, the engine may run at elevated idle and hot temperatures for an extended period of time. Exhaust gases and exhaust filter components may reach temperatures hot enough to burn people and ignite or melt common materials. Service filter cleaning can only be performed when automatic filter cleaning is active and the machine is in a safe state. Three conditions for a safe start are: Park brake applied FNR in neutral Engine running at idle Service cleaning is ONLY available when the exhaust filter reaches SERVICE soot level restriction, indicator is at 100% and red, STOP indicator is flashing, and an alarm is sounding. A popup will appear on the advanced display unit (ADU) stating that engine power is limited and to contact service representative for service filter cleaning. Once service cleaning is activated, the cleaning process will continue until one of the following occurs: Exhaust filter restriction level returned to LOW. Park brake is released, FNR is moved out of neutral, or engine speed increased by means other than the engine control unit (ECU). 3.5 hours has elapsed. Service cleaning is cancelled. Fuel level very low. Diagnostic trouble code (DTC) becomes active. During service filter cleaning, the ECU takes control of the engine speed and attempts to increase the exhaust temperature by employing exhaust temperature management (ETM); which restricts air flow and doses fuel into the exhaust to raise exhaust temperatures. This process can increase the exhaust temperatures (before the diffuser) above 550°C (1021°F). Auto shutdown and auto idle will be disabled during service filter cleaning. For more information on auto shutdown and auto idle during a service filter cleaning, see Exhaust Aftertreatment Circuits Theory of Operation . (Group 9015-15.) To initiate service filter cleaning, see CAN Monitor Unit (CMU)—Exhaust Filter . (Group 9015-16.)
John Deere Engine Adjustments This machine uses a John Deere PowerTech ™ 13.5 liter diesel engine. The engine model is 6135HDW05. To identify the model of engine, see Engine Serial Number Plate Information . (CTM104919). For adjustment information on John Deere PowerTech ™ engines, model 6135HDW05 not contained in this group, see the following: General Tune-Up Recommendations . (CTM104919). Valve—Clearance Adjustment and Injector Preload (CTM104919). Camshaft to Crankshaft Timing—Check and Adjustment (CTM104919). For additional information, see 6135 PowerTech™ OEM Diesel Engines (Interim Tier 4/Stage III B platform) . (CTM104919.)
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Section 9010 page 31
TM12406-OPERATION AND TEST MANUAL
Section 9010 - ENGINE
Group 25: Tests
Group 25 - Tests John Deere Engine Tests This machine uses a John Deere PowerTech ™ 13.5 liter diesel engine. The engine model is 6135HDW05. To identify the model of engine, see Engine Serial Number Plate Information . (CTM104919). For tests on John Deere PowerTech ™ engines, model 6135HDW05 not contained in this group, see the following: Crankcase Pressure (Blow-By) Test . (CTM104919). Engine Oil Pressure Check . (CTM104919). Mechanical Compression Check . (CTM104919). For additional information, see 6135 PowerTech™ OEM Diesel Engines (Interim Tier 4/Stage III B platform) . (CTM104919.)
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Section 9010 page 32
TM12406-OPERATION AND TEST MANUAL
Section 9010 - ENGINE
Group 25: Tests
Fluid Sampling Procedure Specifications SPECIFICATIONS Engine Speed
Slow Idle
System Fluid Purge Volume (approximate)
100 mL 3.4 oz
Fluid Sample Volume (approximate)
75 mL 2.5 oz
This is the recommended procedure for obtaining oil samples using the John Deere sampling valve. A cap probe, plastic bag, and oil sampling kit for the appropriate system are needed for this procedure. Part numbers for the required items can be found at the end of this procedure. Fluid systems should be sampled at the following intervals: Each system at every oil change prior to changing oil. Power train and hydraulics: 500 hours. Engine oil: 250 hours. Axles and differentials: 500 hours. Engine coolant: 1000 hours.
Machine Preparation [1] - Start the machine and warm system to normal operating temperature. Operate machine functions so that the fluid is agitated throughout the system. [2] - Once the system has reached operating temperature, operate engine at slow idle. Item
Measurement
Specification
Engine
Speed
Slow Idle
[3] - Locate sample valve on unit see Fluid Sampling Test Ports . (Operator′s Manual.) [4] IMPORTANT: Clean dust cap on sample valve prior to removal. This will reduce contamination in sample. Once the area has been cleaned, remove the dust cap from the valve.
Priming Sample Valve Oil must be purged from the system to ensure a representative sample is collected in the test collection bottle. The appropriate amount of waste oil is determined by the distance of the sampling valve from the flow of the system. It is recommended one full sample bottle, equal to 100 mL (3.4 oz), be purged from a remotely mounted valve prior to collecting the sample. [1] - Connect probe to sample valve by placing the probe end into the valve port. [2] -
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Section 9010 page 33
TM12406-OPERATION AND TEST MANUAL
Section 9010 - ENGINE
Group 25: Tests
System Fluid Purge (excavator shown) Press and hold the probe to release an appropriate amount of fluid into a waste container. Item
Measurement
Specification
System Fluid Purge
Volume (approximate)
100 mL 3.4 oz
[3] - Properly dispose of collected waste fluid. [4] - If oil flow needs to be increased to obtain a representative sample, accelerate the flow of the system by increasing the engine speed to high idle while taking the sample.
Obtaining Fluid Sample [1] →NOTE: This step is best done in a clean environment, rather than at the sample site. Place the sample bottle from the sample kit into plastic bag. Seal plastic bag.
Sample Bottle Placed Inside Plastic Bag [2] -
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Section 9010 - ENGINE
Group 25: Tests
Lid Removed From Sample Bottle Remove the lid from the sample container, while keeping bottle inside plastic bag. Move the lid aside within the plastic bag, so that the bottle opening is accessible. When collecting hydraulic or power train samples, be careful to hold the sheet of plastic (located under the lid) to the top of the bottle. This will ensure that the protective plastic is not removed when the lid is taken off. [3] →NOTE: The plastic bag creates a protective covering for the sample so that external contaminants are not introduced into the fluid sample. Holding bag tight across bottle, puncture hole in bag with cap probe line and insert line about 13 mm (0.5 in.) into the sample bottle.
Cap Probe Line inserted Into Sample Bottle [4] -
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TM12406-OPERATION AND TEST MANUAL
Section 9010 - ENGINE
Group 25: Tests
Collecting Sample Fluid (excavator shown) While holding cap probe line inside the bottle, press and hold the cap probe to the valve to release the sample fluid into the bottle that is still secured within the plastic bag. [5] - Fill the sample bottle about 3/4 full of fluid. Item
Measurement
Specification
Fluid Sample
Volume (approximate)
75 mL 2.5 oz
[6] - Once a representative sample has been obtained, remove the tube and return the lid to the container, leaving the lid and bottle inside the plastic bag and the protective plastic sheet attached underneath the lid (if applicable). When properly performed, sample oil will be warm, indicating that all stagnant fluid was removed during the purge process and not sent to the lab. [7] →NOTE: Cap probes are to be used for only one sampling procedure. Install the dust cap to the sample valve, and properly dispose of the cap probe. [8] - Fill out the sample information form completely, and submit the form and sample to the designated regional lab for testing. Service Equipment and Tools Fluid Analysis Sampling Materials Summary Part Number
Description
AT317904
Engine Test Kit
AT303189
Hydraulic and Power Train Test Kit
AT180344
Diesel Fuel Test Kit
AT183016
Coolant Test Kit
TY26349
1/4" Suction Pump Tubing, 100ft.
AT308579
120 mL Sample Bottle
AT315231
Poly Cap Probe
AT321211
Probe Style Sample Valve with Attached Cap, -4 SAE O-Ring
AT306111
Probe Style Sample Valve with Attached Cap, -6 SAE O-Ring
TY26363
Probe Style Sample Valve with Attached Cap, 1/4"-20 NPT
AT306133
Probe Style Sample Valve with Attached Cap, 1/8"-27 NPT
AT320593
Probe Style Sample Valve with Attached Cap, -6 ORFS Female
AT312932
Probe Style Sample Valve with Attached Cap, -8 ORFS Female
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TM12406-OPERATION AND TEST MANUAL
ELECTRICAL SYSTEM
(g) by Belgreen v2.0
Fluid Analysis Sampling Materials Summary Part Number
Description
TY26364
90° Push Button Sample Valve with attached Cap, 1/8"-27 NPT
TY26365
Sample Valve Actuator Tubing Adaptor Fitting, KST Series Probe
N/A
Plastic Bag
Engine Slow and Fast Idle Speed Check [1] - Warm engine to operating temperature. Item
Measurement
Specification
Engine
Temperature (operating)
83.5—95°C 183—203°F
[2] - Operate engine at slow idle. [3] →NOTE: Exhaust temperature management and stationary regeneration will affect slow idle speed. Observe display monitor to see if engine slow idle rpm is within specification. Item
Measurement
Specification
Engine
Speed (slow idle)
900 rpm
[4] - Operate engine at fast idle. [5] - Observe display monitor to see if engine fast idle rpm is within specification. Item
Measurement
Specification
Engine
Speed (fast idle)
2250 rpm
[6] - If engine slow and fast idle are not within specification check the following: Check for diagnostic trouble codes (DTCs) see Can Monitor Unit (CMU)-Codes . (Group 9015-16.) Check engine control unit (ECU). See Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.)
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Section 9015 page 37
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TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
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, Component Location, and Wiring Diagram Master Legend ................ 10 System Functional Schematic and Section Legend ............................................................................ 19 Power and Ground Component Location ............................................................................................ 48 Front Frame Harness (W2) Component Location ................................................................................ 50 Front Frame Harness (W2) Wiring Diagram ........................................................................................ 52 Cab Harness (W3) Component Location ............................................................................................. 57 Cab Harness (W3) Wiring Diagram ..................................................................................................... 61 Transmission Control Harness (W4) Component Location .................................................................. 72 Transmission Control Harness (W4) Wiring Diagram .......................................................................... 73 Clutch Control Harness (W5) Component Location ............................................................................. 75 Clutch Control Harness (W5) Wiring Diagram ..................................................................................... 77 Retarder Control Harness (W6) Component Location ......................................................................... 79 Retarder Control Harness (W6) Wiring Diagram ................................................................................. 81 Output Speed Sensor Harness (W7) Component Location .................................................................. 83 Output Speed Sensor Harness (W7) Wiring Diagram .......................................................................... 84 Hydraulic Tank Harness (W8) Component Location ............................................................................ 85 Hydraulic Tank Harness (W8) Wiring Diagram .................................................................................... 86 Hydraulic Harness (W9) Component Location .................................................................................... 87 Hydraulic Harness (W9) Wiring Diagram ............................................................................................ 89 Rear Lights Harness (W10) Component Location ............................................................................... 94 Rear Lights Harness (W10) Wiring Diagram ....................................................................................... 95 Articulation Harness (W11) Component Location ............................................................................... 96 Articulation Harness (W11) Wiring Diagram ....................................................................................... 97 Rear Frame Harness (W12) Component Location ............................................................................... 98 Rear Frame Harness (W12) Wiring Diagram ..................................................................................... 100 Front Work Lights Harness (W13) Component Location ................................................................... 105 Front Work Lights Harness (W13) Wiring Diagram ........................................................................... 106 Rear Work Lights Harness (W14) Component Location .................................................................... 107 Rear Work Lights Harness (W14) Wiring Diagram ............................................................................ 108 AM/FM Radio Harness (W15) Component Location ........................................................................... 109 AM/FM Radio Harness (W15) Wiring Diagram ................................................................................... 110 Air Conditioner Unit Harness (W16) Component Location ................................................................ 111 Air Conditioner Unit Harness (W16) Wiring Diagram ........................................................................ 113 Engine Harness (W17) Component Location .................................................................................... 118 Engine Harness (W17) Wiring Diagram ............................................................................................ 121 Engine Interface Harness (W18) Component Location ..................................................................... 126 Engine Interface Harness (W18) Wiring Diagram ............................................................................. 128 Engine Oil Pressure Sensor Harness (W19) Component Location ..................................................... 135 Engine Oil Pressure Sensor Harness (W19) Wiring Diagram ............................................................. 136 Engine Crankshaft Sensor Harness (W20) Component Location ...................................................... 137 Engine Crankshaft Sensor Harness (W20) Wiring Diagram .............................................................. 138 Exhaust Aftertreatment Harness (W21) Component Location .......................................................... 139 Exhaust Aftertreatment Harness (W21) Wiring Diagram .................................................................. 140 Rear View Camera Harnesses (W22 and W23) Component Location ............................................... 141 Rear View Camera Front Frame Harness (W22) Wiring Diagram ...................................................... 142 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Rear View Camera Rear Frame Harness (W23) Wiring Diagram ....................................................... 143 Diesel Fired Coolant Heater (DFCH) Harnesses (W24 and W25) Component Location ..................... 144 Diesel Fired Coolant Heater (DFCH) Harness (W24) Wiring Diagram ............................................... 146 Diesel Fired Coolant Heater (DFCH) Control Harness (W25) Wiring Diagram ................................... 147 JDLink™ Harnesses (W6002 and W6003) Component Location ........................................................ 148 JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram ............................. 150 JDLink™ Satellite (SAT) Harness (W6003) Wiring Diagram—If Equipped .......................................... 152 Group 15 - Sub-System Diagnostics ................................................................................................. 153 24-Volt Power and Ground Circuits Theory of Operation .................................................................. 154 12-Volt Power Circuits Theory of Operation ...................................................................................... 158 Controller Area Network (CAN) Circuit Theory of Operation ............................................................. 161 Start and Charge Circuits Theory of Operation ................................................................................. 164 Cold Start Aid Circuits Theory of Operation ...................................................................................... 169 Engine Control Unit (ECU) Circuits Theory of Operation ................................................................... 172 Exhaust Aftertreatment Circuits Theory of Operation ...................................................................... 186 Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation ................................... 190 Chassis Control Unit (CCU) Circuits Theory of Operation .................................................................. 197 CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation ................ 203 Dump Body Control and Gear Limit Circuits Theory of Operation ..................................................... 206 Differential Lock Circuits Theory of Operation .................................................................................. 214 Axle Cooling and Lubrication Circuits Theory of Operation ............................................................... 222 Hydraulic Fan Control Circuits Theory of Operation .......................................................................... 226 Suspension Height Control Circuit Theory of Operation ................................................................... 234 Park Brake Circuit Theory of Operation ............................................................................................ 238 Service Brake Light and Brake Accumulator Low Pressure Circuits Theory of Operation ................. 241 Headlights and Tail Lights Circuits Theory of Operation ................................................................... 244 Turn Lights and Four-Way Hazard Lights Circuits Theory of Operation ............................................ 247 Work Lights and Rotating Beacon Circuits Theory of Operation ....................................................... 250 Stairwell and Service Lights Circuits Theory of Operation ................................................................ 252 Backup Alarm and Backup Lights Circuits Theory of Operation ........................................................ 255 Horn Circuit Theory of Operation ...................................................................................................... 258 Rear View Camera Circuit Theory of Operation ................................................................................ 260 Windshield Wipers and Washers Circuits Theory of Operation ......................................................... 262 Air Conditioner and Heater Circuits Theory of Operation .................................................................. 265 Electric Mirror Circuit Theory of Operation ....................................................................................... 270 Heated Seat and Air Seat Compressor Circuits Theory of Operation ................................................ 273 Tire Pressure Monitoring (TPM) System Theory of Operation ........................................................... 275 Onboard Weighing (OBW) Controller Circuit Theory of Operation .................................................... 278 Turbo Spin Down and Auto Shutdown Circuits Theory of Operation ................................................. 284 JDLink™ Circuit Theory of Operation ................................................................................................ 287 Group 16 - Monitor Operation ............................................................................................................ 289 CAN Monitor Unit (CMU)—Service Mode ........................................................................................... 289 CAN Monitor Unit (CMU)—Site Limits ................................................................................................ 290 CAN Monitor Unit (CMU)—Codes ....................................................................................................... 291 CAN Monitor Unit (CMU)—CCU Readings .......................................................................................... 293 CAN Monitor Unit (CMU)—ECU Readings .......................................................................................... 294 CAN Monitor Unit (CMU)—TCU Readings .......................................................................................... 295 CAN Monitor Unit (CMU)—OBW Readings ......................................................................................... 295 CAN Monitor Unit (CMU)—Calibrations ............................................................................................. 297 CAN Monitor Unit (CMU)—Monitor .................................................................................................... 297 CAN Monitor Unit (CMU)—Machine Settings ..................................................................................... 298 CAN Monitor Unit (CMU)—Machine Options ...................................................................................... 298 CAN Monitor Unit (CMU)—Software Delivery .................................................................................... 300 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
CAN Monitor Unit (CMU)—Security ................................................................................................... 302 CAN Monitor Unit (CMU)—Exhaust Filter ........................................................................................... 305 Group 20 - References ......................................................................................................................... 307 Electrical Component Specifications ................................................................................................. 307 Service ADVISOR™ Connection Procedure ....................................................................................... 312 Service ADVISOR™ Diagnostic Application ....................................................................................... 313 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application ........................ 314 Intermittent Diagnostic Trouble Code (DTC) Diagnostics ................................................................. 317 JDLink™ Connection Procedure ........................................................................................................ 317 Chassis Control Unit (CCU) Outputs .................................................................................................. 318 Alternator Test .................................................................................................................................. 321 Relay Test ......................................................................................................................................... 322 Diode Test ........................................................................................................................................ 323 Controller Area Network (CAN) Diagnostics ...................................................................................... 324 Controller Area Network (CAN) Resistor Test .................................................................................... 330 Hydraulic Pressure Switches Test ..................................................................................................... 331 Hydraulic Pressure Sensor Diagnostic Procedure ............................................................................. 332 Hydraulic Temperature Sensors Test ................................................................................................ 333 Dump Body Position Sensor Test ...................................................................................................... 334 Dump Body Position Sensor Calibration ........................................................................................... 336 Dump Body Position Sensor Adjustment .......................................................................................... 337 Slope Sensor Calibration .................................................................................................................. 338 Steering Column Switch Test ............................................................................................................ 338 Transmission Solenoids and Sensors Tests ...................................................................................... 340 On Board Weighing (OBW) Calibration ............................................................................................. 342 TPM—Activating Tire Pressure Monitoring System ........................................................................... 343 TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool ................................. 344 TPM—Programming Using Sensor Identification Numbers ................................................................ 346 TPM—Cold Inflation Pressure (CIP) Setup ......................................................................................... 346 TPM—Alarm Setup ............................................................................................................................ 348 TPM—Delete Sensors ........................................................................................................................ 348 TPM—SmartWave® Advanced Maintenance Tool Diagnostics ......................................................... 349 TPM—Tire Pressure Sensor Remove and Install ................................................................................ 350 Electronic Controllers Remove and Install ........................................................................................ 352 Program Monitor Display Unit (MDU) ................................................................................................ 352 Monitor Display Unit Remove and Install .......................................................................................... 353 Connector Terminal Test Diagnostic Procedure ................................................................................ 355 Replace Metri-Pack® (Push Type) Connectors ................................................................................. 356 Replace Metri-Pack® Connectors ..................................................................................................... 358 Replace DEUTSCH® Circular Connectors ......................................................................................... 360 Replace DEUTSCH® Rectangular or Triangular Connectors ............................................................. 361 Install DEUTSCH® Contact ............................................................................................................... 363 Replace WEATHER PACK® Connector .............................................................................................. 364 Install WEATHER PACK® Contact ..................................................................................................... 365 Replace CINCH™ Connectors ........................................................................................................... 367 Install CINCH™ Contact .................................................................................................................... 369 Repair 32 and 48 Way CINCH™ Connectors ..................................................................................... 371 Remove Connector Body from Blade Terminals ............................................................................... 374
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TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 05: System Information
Group 05 - System Information Electrical Diagram Information Explanation of Wire Markings →NOTE: All system functional schematics, circuit schematics, and wiring diagrams are shown with key switch in the OFF position.
System Functional Schematic Diagram
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Section 9015 page 1
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 05: System Information
System Functional Schematic Example LEGEND: 1 2 3 4 5 7 <- Go to Section TOC
Continuity Chart Power Wires Routing Location Information Wire Identification Ground Wires Section Number Section 9015 page 2
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
8 9 10 11 12 13
Group 05: System Information
Component Name Component Identification Number Component Schematic Symbol Connector Identification Number Connector Connector Pin Information
The system functional schematic is made up of equal sections to simplify searching the schematic. Each section of the system functional schematic is assigned a number (7). The system functional schematic is formatted with power supply wires (2) shown near the top of the drawing and ground wires (5) near the bottom. The schematic may contain some harness or connector information. When connector information is shown, it will be displayed as a double chevron (12) with a component identification number (11) corresponding to the connector identification number. Connector pin information (13) will be displayed in a text size smaller than that of the connector identification number. Each electrical component is shown by a schematic symbol (10), the component name (8), and a component identification number (9). A component identification number and name will remain the same throughout the Operation and Test Technical Manual. This will allow for easy cross-referencing of all electrical drawings (schematics, wiring diagrams, and component location). Routing location information (3) is presented to let the reader know when a wire is connected to a component in another section. TO and FROM statements identify when power is going “To” or coming “From” a component in a different location. The section and component identification number are given in the first line of information and any pin information for the component is given in parenthesis in the second line. In this example, power is going TO section 23, component B14 on pin C4.
Wiring Diagram
Wiring Diagram Example LEGEND: <- Go to Section TOC
Section 9015 page 3
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
1 2 3 4 5 6 7 8 9 10
Group 05: System Information
Component Identification Number Connector Connector End View Wire Harness Wire Number Wire Splice Wire End #1 Termination Location Wire Number Wire Color Wire End #2 Termination Location
Each harness on the machine is drawn showing connectors, wires, and splices. A “W” component identification number identifies harnesses. (W6, etc.) The harness is drawn showing spatial arrangement of components and branches. A component identification or connector number (1) identifies each component. The wire harness (4) is terminated by a top or side view of the connector (2). If more than one wire is supplied to the connector, a harness side connector end view (3) is provided. Each wire number is labeled for the appropriate pin. If only one wire is supplied to the connector, the wire number (5) is indicated. An “X” component identification number of 100 or higher identifies splices (6). Each splice lists side A wires and side B wires to differentiate the side of the harness that the wires come from. A wire legend is provided for each harness. A component identification number is listed in the “END #1” column (7) to indicate the termination location of one end of a wire. In the center, the wire number (8) and wire color (9) are listed. A component identification number in the “END #2” column (10) identifies the opposite end of the wire.
Component Location Diagram The component location diagram is a pictorial view by harness showing location of all electrical components, connectors, harness main ground locations and harness band and clamp location. Each component will be identified by the same identification letter/number and description used in the system functional schematic diagram.
Connector End View Diagram The connector end view diagram is a pictorial end view of the component connectors showing the number of pins in the connector and the wire color and identifier of the wire in every connector. Each component will be identified by the same identification letter/number and description used in the system functional schematic diagram.
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Section 9015 page 4
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 05: System Information
Electrical Schematic Symbols
Electrical Schematic Symbols
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Section 9015 page 5
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Section 9015 - ELECTRICAL SYSTEM
LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 <- Go to Section TOC
Group 05: System Information
Battery Wire Splice Fuse Circuit Breaker Fusible Link Power Outlet Alternator Air Conditioner Compressor Compressor Liquid Pump Antenna Diode Zener Diode Capacitor Magnet Flasher Buzzer Horn Alarm Electromagnet Internal Ground Single Point Ground External Ground Sensor Sensor with Normally Open Switch Speed Sensor Rotary Sensor Single Element Bulb Dual Element Bulb Solenoid Operated Hydraulic Valve with Suppression Diode Solenoid Normally Open Solenoid Normally Closed Starter Motor Starter Motor DC Motor DC Stepping Motor Wiper Motor Blower Motor Servo Motor Speedometer Tachometer Temperature Gauge Liquid Level Gauge Gauge Hourmeter Resistor Variable Resistor Manually Adjusted Variable Resistor Multi-Pin Connector Single Pin Connector Connector 4 Pin Relay 5 Pin Relay 5 Pin Relay with Internal Suppression Diode 5 Pin Relay with Internal Suppression Resistor Key Switch Temperature Switch Normally Open Temperature Switch Normally Closed Pressure Switch Normally Open Pressure Switch Normally Closed Liquid Level Switch Normally Open Liquid Level Switch Normally Closed Momentary Switch Normally Open Momentary Switch Normally Closed Toggle Switch Normally Open Toggle Switch Normally Closed Section 9015 page 6
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
67 68 69 70 71 72 73 74 75 76 77 78 79 80
<- Go to Section TOC
Group 10: System Diagrams
2 Way Toggle Switch Normally Open 2 Way Toggle Switch Normally Closed Manual Switch Operation Push Switch Operation Pull Switch Operation Turn Switch Operation Toggle Switch Operation Pedal Switch Operation Key Switch Operation Detent Switch Operation Temperature Sensor Solar Sensor Pressure Sensor Liquid Level Sensor
Section 9015 page 7
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Group 10 - System Diagrams Fuse and Relay Specifications
Fuse Block LEGEND: F1 25-Button Sealed Switch Module (SSM) and Interior Light 10-Amp Fuse F2 Spare 10-Amp Fuse F3 Horn 10-Amp Fuse F4 Brake Light Switch 10-Amp Fuse F5 Stair and Service Lights Switches 10-Amp Fuse F6 Chassis Control Unit (CCU) (VP2) 10-Amp Fuse F7 Chassis Control Unit (CCU (VP3) 20-Amp Fuse F8 CAN Monitor Unit (CMU) Unswitched Power 10-Amp Fuse F9 24V/12V Converter (15A) Unswitched Power 15-Amp Fuse F10 24V/12V Converter (25A) Unswitched Power 25-Amp Fuse F11 Transmission Control Unit (TCU) Unswitched Power 10-Amp Fuse F12 Service ADVISOR ™ Diagnostic Connector Unswitched Power 10-Amp Fuse F13 JDLink ™ Unswitched Power 10-Amp Fuse F14 Engine Control Unit (ECU) Unswitched Power 15-Amp Fuse F15 Fuel Dosing Pump 15-Amp Fuse F16 Low Pressure Fuel Pump 15-Amp Fuse F17 Headlights, Tail Lights, and Turn Lights 15-Amp Fuse F18 Wiper Motor 10-Amp Fuse F19 Mirror Switch 10-Amp Fuse F20 Air Conditioner Unit 10-Amp Fuse F21 Chassis Control Unit (CCU) (VELX) Switched Power 5-Amp Fuse F22 CAN Monitor Unit (CMU) and 15-Button Sealed Switch Module (SSM) Switched Power 10-Amp Fuse F23 24V/12V Converter Switched Power 10-Amp Fuse F24 On Board Weighing (OBW) and Tire Pressure Monitoring System (TPM) 10-Amp Fuse F25 Transmission Control Unit (TCU) Switched Power 10-Amp Fuse F26 Auto Greasing (if equipped) and Rear View Monitor (if equipped) 5-Amp Fuse F27 JDLink™ Switched Power 5-Amp Fuse F28 Engine Control Unit (ECU) Switched Power 5-Amp Fuse F29 Spare F30 Seat Compressor and Brake Accumulator Low Pressure Switch 10-Amp Fuse F31 Lighter 10-Amp Fuse F32 2-Way Radio 10-Amp Fuse F33 12-Volt Converter Monitoring 10-Amp Fuse <- Go to Section TOC
Section 9015 page 8
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
F34 F35 F36 F37 X29 X30
Group 10: System Diagrams
12-Volt Power Outlet 10-Amp Fuse AM/FM Radio Switched Power 10-Amp Fuse Ground Speed Radar 10-Amp Fuse AM/FM Radio Memory 5-Amp Fuse Fuse Block Unswitched Power Terminal Fuse Block Switched Power Terminal The following components are not located on the fuse block: F44—Coolant Heater Control 15-Amp Fuse (inline) (if equipped) F46—Coolant Heater Module 5-Amp Fuse (inline) (if equipped) F50—Main 60-Amp Circuit Breaker F51—Fuel Filter Heater 20-Amp Circuit Breaker F52—JDLink™ Return (ground) 5-Amp Fuse (in-line) K1—Ignition Relay K2—Starter Relay
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Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
System Functional Schematic, Component Location, and Wiring Diagram Master Legend →NOTE: A3—Engine Control Unit (ECU) (SE14) (W18) A3 indicates component identification number. Engine control unit (ECU) indicates component name. SE14 indicates section number of System Functional Schematic where component is located. W18 is the identification number of the Component Location and Harness Connector (with wire and pin location) drawings for the component. This would indicate that the engine control unit (ECU) is connected to W18 Engine Interface Harness. A1—15-Button Sealed Switch Module (SSM) (OC4) ( SE2 ) ( W3 ) A2—25-Button Sealed Switch Module (SSM) (OC3) ( SE2 ) ( W3 ) A3—Engine Control Unit (ECU) ( SE36 , SE37 , SE38 , SE41 ) ( W18 ) A4—Ground Speed Radar Unit ( SE27 ) ( W12 ) A5—Transmission Control Unit (TCU) ( SE5 ) ( W4 ) A7—CAN Monitor Unit (CMU) ( SE3 ) ( W3 ) A8—Chassis Control Unit (CCU) ( SE7 , SE8 , SE9 , SE10 , SE11 , SE12 , SE13 , SE14 , SE15 , SE16 , SE18 , SE19 , SE20 , SE22 , SE23 , SE25 , SE27 , SE28 , SE31 ) A9—Rear View Monitor (if equipped) ( SE17 ) ( W3 ) A10—Rear View Camera (if equipped) ( SE17 ) A12—AM/FM Radio ( SE26 ) ( W15 ) A15—Coolant Heater Control Module (if equipped) ( SE3 ) ( W25 ) A16—Air Conditioner Unit ( SE30 ) ( W16 ) A18—Onboard Weighing (OBW) Controller ( SE32 ) ( W12 ) A19—Tire Pressure Monitoring (TPM) System Controller (if equipped) ( SE33 ) ( W12 ) A6000—JDLink™ Modular Telematics Gateway (MTG) Control Unit ( SE34 ) ( W6002 ) A6001—GPS/Cellular Antenna ( SE34 ) ( W6002 ) A6002—Satellite (SAT) Module Control Unit (if equipped) ( SE35 ) ( W6002 ) A6003—Satellite Antenna (if equipped) ( SE35 ) ( W6002 ) B3—Electric Horn ( SE19 ) ( W2 ) B4—Left OBW Strain Gauge ( SE32 ) ( W12 ) B5—Right OBW Strain Gauge ( SE32 ) ( W12 ) B6—Dump Body Position Sensor ( SE10 ) ( W12 ) B7—Left Fan Speed Sensor ( SE12 ) ( W2 ) B8—Right Fan Speed Sensor ( SE12 ) ( W2 ) B9—Hydraulic Filter Restriction Switch ( SE11 ) ( W8 ) B10—Right Side Height Sensor ( SE8 ) ( W9 ) B11—Left Side Height Sensor ( SE8 ) ( W9 ) B12—Main Hydraulic Pressure Sensor ( SE8 ) ( W9 ) B13—Secondary Steering Pressure Sensor ( SE7 ) ( W9 ) B15—Park Brake Pressure Switch ( SE11 ) ( W11 ) B16—Dump Body Lock Sensor ( W10 ) B17—Transmission Filter Restriction Switch ( SE5 ) ( W9 ) B18—Accelerator Pedal Position Sensor ( SE36 ) ( W3 ) B19—Engine Coolant Loss Service Switch ( SE36 ) ( W18 ) B20—Engine Coolant Loss Alarm Switch ( SE36 ) ( W18 ) B23—EBS Brake Switch ( SE19 ) ( W3 ) B24—Service Brake Light Switch ( SE19 ) ( W3 ) B25—Dump Body Lever Position Sensor ( SE10 ) ( W3 ) B26—Articulation Angle Sensor ( SE11 ) ( W9 ) B27—Air Conditioner High/Low-Pressure Switch ( SE28 ) ( W3 ) B28—Air Conditioner Freeze Control Switch ( SE29 ) ( W16 ) B29—Air Conditioner Evaporator Temperature Sensor ( SE29 ) ( W16 ) B30—Air Conditioner Evaporator Inlet Sensor ( SE29 ) ( W16 ) B35—Brake Accumulator Low-Pressure Switch ( SE11 ) ( W9 ) B37—Fuel Level Sensor ( SE7 ) ( W2 ) <- Go to Section TOC
Section 9015 page 10
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
B38—Retarder Temperature Sensor ( SE6 ) ( W6 ) B39—Transmission Sump Temperature Sensor ( SE6 ) ( W6 ) B40—Turbine Speed Sensor ( SE5 ) ( W5 ) B41—Transmission Clutch A (primary) Speed Sensor ( SE6 ) ( W5 ) B42—Transmission Clutch C (secondary) Speed Sensor ( SE6 ) ( W6 ) B43—Output Speed Sensor ( SE6 ) ( W9 ), ( W7 ) B45—Left Speaker ( SE26 ) ( W15 ) B46—Right Speaker ( SE26 ) ( W15 ) B48—Tire Pressure Monitoring (TPM) System Sensor (right front) (if equipped) ( SE33 ) B49—Tire Pressure Monitoring (TPM) System Sensor (right middle) (if equipped) ( SE33 ) B50—Tire Pressure Monitoring (TPM) System Sensor (right rear) (if equipped) ( SE33 ) B51—Tire Pressure Monitoring (TPM) System Sensor (left rear) (if equipped) ( SE33 ) B52—Tire Pressure Monitoring (TPM) System Sensor (left middle) (if equipped) ( SE33 ) B53—Tire Pressure Monitoring (TPM) System Sensor (left front) (if equipped) ( SE33 ) B54—Hydraulic Temperature Sensor ( SE11 ) ( W8 ) B55—Rear Axle Pressure Sensor ( SE15 ) ( W12 ) B58—Front Axle Differential Lock Pressure Sensor ( SE13 ) ( W2 ) B59—Middle Axle Differential Lock Pressure Sensor ( SE14 ) ( W12 ) B60—Rear Axle Differential Lock Pressure Sensor ( SE15 ) ( W12 ) B61—Front Axle Temperature Sensor ( SE13 ) ( W2 ) B62—Middle Axle Temperature Sensor ( SE14 ) ( W12 ) B63—Rear Axle Temperature Sensor ( SE13 , SE15 ) ( W12 ) B64—Front Axle Pressure Sensor ( SE13 ) ( W2 ) B65—Middle Axle Pressure Sensor ( SE14 ) ( W12 ) B67—Front Axle Filter Restriction Switch ( SE13 ) ( W2 ) B68—Middle Axle Filter Restriction Switch ( SE14 ) ( W12 ) B69—Rear Axle Filter Restriction Switch ( SE15 ) ( W12 ) B5000—Fuel Dosing Inlet Sensor ( SE42 ) ( W17 ) B5101—Engine Oil Pressure Sensor ( SE39 ) ( W19 ) B5102—Exhaust Manifold Pressure Sensor ( SE39 ) ( W17 ) B5103—Exhaust Gas Recirculation (EGR) Flow Sensor ( SE39 ) ( W17 ) B5104—Intake Manifold Pressure Sensor ( SE39 ) ( W17 ) B5106—Fuel Dosing Outlet Pressure Sensor ( SE42 ) ( W17 ) B5107—High-Pressure Fuel Pressure Sensor ( SE38 ) ( W18 ) B5108—Engine Coolant Pressure Sensor ( SE42 ) ( W17 ) B5109—Diesel Particulate Filter (DPF) Differential Pressure Sensor ( SE42 ) ( W21 ) B5110—Low-Pressure Fuel Pressure Sensor ( SE39 ) ( W18 ) B5200—Fixed Turbo Charger Compressor Outlet Temperature Sensor ( SE40 ) ( W17 ) B5204—Exhaust Filter Temperature Module ( SE42 ) ( W21 ) B5205—Charge Air Cooler Outlet Temperature Sensor ( SE40 ) ( W17 ) B5206—Manifold Air Temperature Sensor ( SE40 ) ( W17 ) B5207—Exhaust Gas Recirculation (EGR) Temperature Sensor ( SE40 ) ( W17 ) B5208—Engine Coolant Temperature Sensor ( SE40 ) ( W17 ) B5209—Fuel Temperature Sensor ( SE41 ) ( W18 ) B5300—Variable Geometry Turbo (VGT) Speed Sensor ( SE37 ) ( W17 ) B5301—Crankshaft Position Sensor ( SE37 ) ( W20 ) B5302—Camshaft Position Sensor ( SE37 ) ( W17 ) B5500—Intake Air Sensor ( SE37 ) ( W17 ) B5511—DOC Inlet Temperature Sensor ( SE42 ) ( W21 ) B5512—DOC Outlet Temperature Sensor ( SE42 ) ( W21 ) B5513—DPF Outlet Temperature Sensor ( SE42 ) ( W21 ) B5600—Water-in-Fuel (WIF) Sensor ( SE37 ) ( W18 ) E1—Right Rear Turn Light ( SE21 ) ( W10 ) E2—Left Rear Turn Light ( SE21 ) ( W10 ) E3—Right Front Turn Light ( SE19 ) ( W2 ) E4—Right Low Beam Headlight ( SE19 ) ( W2 ) E5—Right High Beam Headlight ( SE19 ) ( W2 ) E6—Left Front Turn Light ( SE19 ) ( W2 ) E7—Left Low Beam Headlight ( SE19 ) ( W2 ) E8—Left High Beam Headlight ( SE19 ) ( W2 ) E9—Interior Light ( SE2 ) ( W3 ) <- Go to Section TOC
Section 9015 page 11
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
E10—Right Rear Park/Brake Light ( SE21 ) ( W10 ) E11—Left Rear Park/Brake Light ( SE21 ) ( W10 ) E12—License Plate Light (if equipped) ( SE21 ) ( W12 ) E13—Coolant Heater Unit (if equipped) ( SE3 ) ( W24 ) E14—Left Stairwell Light (if equipped) ( SE9 ) ( W14 ) E15—Right Backup Light ( SE21 ) ( W12 ) E16—Left Backup Light ( SE21 ) ( W12 ) E17—Left Articulation Backup Light ( SE18 ) ( W14 ) E18—Right Articulation Backup Light ( SE18 ) ( W14 ) E19—Right Stairwell Light ( SE9 ) ( W3 ) E21—Service Light ( SE9 ) ( W2 ) E28—Left Front Work Light ( SE18 ) ( W13 ) E29—Right Front Work Light ( SE18 ) ( W13 ) F1—25-Button Sealed Switch Module (SSM) and Interior Light 10-Amp Fuse ( SE2 ) F2—Spare 10-Amp Fuse F3—Horn 10-Amp Fuse ( SE19 ) F4—Brake Light Switch 10-Amp Fuse ( SE19 ) F5—Stair and Service Lights Switches 10-Amp Fuse ( SE9 ) F6—Chassis Control Unit (CCU) (VP2) 10-Amp Fuse ( SE7 ) F7—Chassis Control Unit (CCU) (VP3) 20-Amp Fuse ( SE7 ) F8—CAN Monitor Unit (CMU) Unswitched Power 10-Amp Fuse ( SE3 ) F9—24V/12V Converter (15A) Unswitched Power 15-Amp Fuse ( SE25 ) F10—24V/12V Converter (25A) Unswitched Power 25-Amp Fuse ( SE25 ) F11—Transmission Control Unit (TCU) Unswitched Power 10-Amp Fuse ( SE5 ) F12— Service ADVISOR ™ Diagnostic Connector Unswitched Power 10-Amp Fuse ( SE4 ) F13— JDLink ™ Unswitched Power 10-Amp Fuse ( SE34 ) F14—Engine Control Unit (ECU) Unswitched Power 15-Amp Fuse ( SE35 ) F15—Fuel Dosing Pump 15-Amp Fuse ( SE37 ) F16—Low-Pressure Fuel Pump 15-Amp Fuse ( SE37 ) F17—Headlights, Tail Lights, and Turn Lights 15-Amp Fuse ( SE20 ) F18—Wiper Motor 10-Amp Fuse ( SE22 ) F19—Mirror Switch 10-Amp Fuse ( SE24 ) F20—Air Conditioner Unit 10-Amp Fuse ( SE28 ) F21—Chassis Control Unit (CCU) (VELX) Switched Power 5-Amp Fuse ( SE7 ) F22—CAN Monitor Unit (CMU) and 15-Button Sealed Switch Module (SSM) Switched Power 10-Amp Fuse ( SE3 ) F23—24V/12V Converter Switched Power 10-Amp Fuse ( SE25 ) F24—On Board Weighing (OBW) and Tire Pressure Monitoring System (TPM) 10-Amp Fuse ( SE32 ) F25—Transmission Control Unit (TCU) Switched Power 10-Amp Fuse ( SE5 ) F26—Auto Greasing (if equipped) and Rear View Monitor (if equipped) 5-Amp Fuse ( SE17 ) F27—JDLink™ Switched Power 5-Amp Fuse ( SE34 ) F28—Engine Control Unit (ECU) Switched Power 5-Amp Fuse ( SE35 ) F29—Spare F30—Seat Compressor and Brake Accumulator Low-Pressure Switch 10-Amp Fuse ( SE16 ) F31—Lighter 10-Amp Fuse ( SE26 ) F32—2-Way Radio 10-Amp Fuse ( SE26 ) F33—12-volt Converter Monitoring 10-Amp Fuse ( SE25 ) F34—12-volt Power Outlet 10-Amp Fuse ( SE26 ) F35—AM/FM Radio Switched Power 10-Amp Fuse ( SE26 ) F36—Ground Speed Radar 10-Amp Fuse ( SE27 ) F37—AM/FM Radio Memory 5-Amp Fuse ( SE26 ) F38—Not Used F39—Not Used F40—Not Used F41—Not Used F42—Not Used F44—Coolant Heater Control 15-Amp Fuse (inline) (if equipped) ( SE3 ) ( W24 ) F46—Coolant Heater Module 5-Amp Fuse (inline) (if equipped) ( SE3 ) ( W25 ) F50—Main 60-Amp Circuit Breaker ( W2 ) F51—Fuel Filter Heater 20-Amp Circuit Breaker ( W2 ) F52—JDLink™ Return (ground) 5-Amp Fuse (in-line) ( SE34 ) ( W2 ) G1—Battery ( SE1 ) (2 used) <- Go to Section TOC
Section 9015 page 12
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
G3—Alternator ( SE2 ) ( W18 ) H1—Backup Alarm ( W12 ) H12—Left Dump Body Under-Loaded Light (yellow) ( SE31 ) ( W3 ) H13—Left Dump Body Fully Loaded Light (green) ( SE31 ) ( W3 ) H14—Left Dump Body Over-Loaded Light (red) ( SE31 ) ( W3 ) H21—Rotating Beacon (if equipped) ( SE21 ) ( W3 ) H22—Buzzer ( SE3 ) ( W3 ) K1—Ignition Relay ( SE1 ) ( W2 ) K2—Starter Relay ( SE1 ) ( W18 ) M1—Starter Motor ( SE1 ) ( W18 ) M2—Heater Control Valve Actuator ( SE30 ) ( W16 ) M3—Front Windshield Wiper Motor ( SE23 ) ( W3 ) M4—Blower Motor ( SE30 ) ( W16 ) M5—Front Windshield Washer Pump Motor ( SE23 ) ( W2 ) M6—Recirculation Vent Actuator ( SE30 ) ( W16 ) M7—Defrost and Middle Vent Actuator ( SE30 ) ( W16 ) M8—Floor Vent Actuator ( SE30 ) ( W16 ) M9—Left Mirror Servo Motors (if equipped) ( SE24 ) M10—Right Mirror Servo Motors (if equipped) ( SE24 ) M11—Air Seat Compressor ( SE16 ) M12—Rear Window Wiper Motor ( SE22 ) ( W3 ) M13—Rear Window Washer Pump Motor ( SE22 ) ( W2 ) R1—Engine Interface Harness CAN 1 Termination Resistor ( SE35 ) ( W18 ) R2—Engine CAN Termination Resistor ( SE37 ) ( W17 ) R3—Cab CAN 2 Termination Resistor ( SE4 ) ( W3 ) R4—OBW/TPMS CAN 2 Termination Resistor ( SE33 ) ( W12 ) R7—Hydraulic Harness CAN 1 Termination Resistor ( SE5 ) ( W9 ) R8—Lighter ( SE26 ) ( W3 ) R10—Fuel Filter Heater ( SE16 ) ( W2 ) R11—Blower Motor Resistor/Thermofuse (if equipped) ( SE30 ) ( W16 ) R12—Left Mirror Defrost (if equipped) ( SE24 ) R13—Right Mirror Defrost (if equipped) ( SE24 ) R14—Seat Cushion Heater ( SE16 ) R15—Back Cushion Heater ( SE16 ) S1—Battery Disconnect Switch ( SE1 ) ( W2 ) S2—Steering Column Switch ( SE20 ) ( W3 ) S3—Side Mirrors Positioning Switch (if equipped) ( SE24 ) ( W3 ) S4—Remote Stairwell Light Switch ( SE9 ) ( W9 ) S5—Differential Lock Floor Switch ( SE13 ) ( W9 ) S6—Service Light Switch ( SE9 ) S7—Remote Suspension Lowering Switch ( SE8 ) ( W2 ) U1—24 V to 12 V DC Converter ( SE25 ) V1—Ignition Relay Diode ( SE1 ) ( W2 ) V2—Starter Relay Diode ( SE1 ) ( W18 ) V3—Starter Solenoid Diode ( SE1 ) ( W18 ) V4—Air Conditioner Compressor Clutch Diode ( SE28 ) ( W2 ) V7—Left Side Reversing Fan Solenoid Diode ( SE12 ) V8—Right Side Reversing Fan Solenoid Diode ( SE12 ) V10—Dump Body Lever Detent Magnet Diode ( SE10 ) ( W3 ) U1—24 V to 12 V DC Converter ( SE25 ) ( W31 ) W2 —Front Frame Harness W3 —Cab Harness W4 —Transmission Control Harness W5 —Clutch Control Harness W6 —Retarder Control Harness W7 —Output Speed Sensor Harness W8 —Hydraulic Tank Harness W9 —Hydraulic Harness W10 —Rear Lights Harness W11 —Articulation Harness W12 —Rear Frame Harness <- Go to Section TOC
Section 9015 page 13
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
W13 —Front Work Lights Harness W14 —Rear Work Light Harness W15 —AM/FM Radio Harness W16 —Air Conditioner Unit Harness W17 —Engine Harness W18 —Engine Interface Harness W19 —Engine Oil Pressure Sensor Harness W20 —Engine Crankshaft Sensor Harness W21 —Exhaust Aftertreatment Harness W22 —Rear View Camera Front Frame Harness W23 —Rear View Camera Rear Frame Harness W24 —Diesel Fired Coolant Heater Harness W25 —Diesel Fired Coolant Heater Control Harness W28 —TPMS Antenna (if equipped) ( SE33 ) W29 —AM/FM Radio Antenna ( W15 ) W30 —Engine Interface Harness Ground W31 —Cab Ground ( W3 ) W32 —Starter Motor Ground W33 —Front Frame Harness Ground W34 —Hydraulic Harness Ground ( W9 ) W35 —Air Conditioner Unit Ground ( W3 ), ( W16 ) W36 —Machine Frame-to-Cab Frame Ground Cable W37 —Engine Block-to-Machine Frame Ground Strap W38 —Cab Frame Ground W6002 —JDLink™ Modular Telematics Gateway (MTG) Harness W6003 —JDLink™ Satellite (SAT) Harness X2—Articulation Harness-to-Rear Frame Harness 21-Pin Connector ( W11 ), ( W12 ) X3—Hydraulic Harness-to-Articulation Harness 21-Pin Connector ( W9 ), ( W11 ) X5—Hydraulic Harness-to-Hydraulic Tank Harness 6-Pin Connector ( W8 ), ( W9 ) X7—Coolant Heater Control Module Harness-to-Coolant Heater Unit Harness 4-Pin Connector ( W24 ), ( W25 ) X8—Cab Harness-to-Hydraulic Harness 31-Pin Connector ( W3 ), ( W9 ) X9—Cab Harness-to-Hydraulic Harness 31-Pin Connector ( W3 ), ( W9 ) X10—Cab Harness-to-Hydraulic Harness 31-Pin Connector ( W3 ), ( W9 ) X11—ECU Connector 1 ( W18 ) X12—ECU Connector 2 ( W18 ) X13—ECU Connector 3 ( W18 ) X14—Cab Harness-to-Front Frame Harness 21-Pin Connector ( W2 ), ( W3 ) X15—Cab Harness-to-Front Frame Harness 9-Pin Connector ( W2 ), ( W3 ) X16—Cab Harness-to-Engine Interface Harness 14-Pin Connector ( W3 ), ( W18 ) X17—Rear Frame Harness-to-Rear Lights Harness 8-Pin Connector ( W10 ), ( W12 ) X19—Hydraulic Harness-to-Transmission Control Harness 2-Pin Connector ( W9 ) ( W4 ) X20—Engine Interface Harness-to-Exhaust Aftertreatment Harness 6-Pin Connector ( W18 ), ( W21 ) X21—Chassis Control Unit (CCU) 48-Pin Connector (J1) ( W3 ) X22—Chassis Control Unit (CCU) 53-Pin Connector (J2) ( W3 ) X23—Chassis Control Unit (CCU) 53-Pin Connector (J3) ( W3 ) X24—Chassis Control Unit (CCU) 1-Pin Connector ( W3 ) X25—Left OBW Load Lights 4-Pin Connector ( W3 ) X26—Right OBW Load Lights 4-Pin Connector ( W3 ) X27—Left Strain Gauge 4-Pin Connector ( W12 ) X28—Right Strain Gauge 4-Pin Connector ( W12 ) X29—Fuse Block Unswitched Power Terminal ( W3 ) X30—Fuse Block Switched Power Terminal ( W3 ) X31—Cab Harness-to-JDLink™ Harness 12-Pin Connector ( W3 ), ( W6002 ) X32 (B27)—Air Conditioner High/Low Pressure Switch 1-Pin Connector ( W3 ) X33 (B27)—Air Conditioner High/Low Pressure Switch 1-Pin Connector ( W3 ) X34—12-volt Power Outlet ( W3 ) X36—Cab Harness-to-Left Mirror Harness 6-Pin Connector (if equipped) ( W3 ) X37—Cab Harness-to-Right Mirror Harness 6-Pin Connector (if equipped) ( W3 ) X38—Cab Harness-to-AM/FM Radio Harness 3-pin Connector ( W3 ), ( W15 ) X40—Service ADVISOR™ Diagnostic 9-Pin Connector ( W3 ) X41—Left 2-Way Radio 2-Pin Connector ( W3 ) <- Go to Section TOC
Section 9015 page 14
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
X42—Right 2-Way Radio 2-Pin Connector ( W3 ) X44—Cab Harness-to-Front Work Lights Harness 3-Pin Connector ( W3 ), ( W13 ) X45—Cab Harness-to-Rear Work Light Harness 4-Pin Connector ( W3 ), ( W14 ) X46—Cab Harness-to-Air Conditioner Control Unit Harness 12-Pin Connector ( W3 ), ( W16 ) X47—Auto Greaser 6-Pin Connector ( W3 ) X48—Auto Greaser 6-Pin Connector ( W9 ) X49 (B23, B24)—Brake Switch 4-Pin Connector (marked as B24) ( W3 ) X50—Remote Charge Positive (+) Post X51—Remote Charge Negative (—) Post X54—Fuse Block ( W3 ) X55—24 V to 12 V DC Converter 6-Pin Connector ( W3 ) X56—24 V to 12 V DC Converter 4-Pin Connector (if equipped) ( W3 ) X65—Seat Heater 2-Pin Connector ( W3 ) X66—Seat Compressor 2-Pin Connector ( W3 ) X67—Rear View Camera Articulation 4-Pin Connector X70—Transmission Control Unit (TCU) 21-Pin Connector ( W9 ) X71—Transmission Control Unit (TCU) 32-Pin Connector ( SE5 ) ( W4 ) X72—Transmission Control Harness-to-Transmission Clutch Control Harness Connector ( W4 ), ( W5 ) X73—Clutch Control Harness-to-Retarder Control Harness 16-Pin Connector ( W5 ), ( W6 ) X74—Retarder Control Harness-to-Output Speed Sensor Harness 2-Pin Connector ( W6 ), ( W7 ) X84—Air Conditioner Control Unit 8-Pin Connector X85—Air Conditioner Control Unit 6-Pin Connector X1000—Splice R51 BLK ( W2 ) X1001—Splice B03 RED ( W2 ) X1002—Splice A34 ORG ( W2 ) X1003—Splice H05 GRN ( W2 ) X1004—Splice L01 BRN( W2 ) X1005—Splice P18 RED ( W2 ) X1006—Splice H14 GRN ( W2 ) X1007—Splice R51 BLK ( W2 ) X1008—Splice P50 RED ( W2 ) X1009—Splice L06 BRN ( W2 ) X1010—Splice L13 BRN ( W2 ) X1050—Splice R51 BLK ( W9 ) X1051—Splice P51 RED ( W9 ) X1052—Splice R37 BLK ( W9 ) X1053—Splice M01 YEL ( W9 ) X1054—Splice M02 GRN ( W9 ) X1055—Splice M05 PUR ( W9 ) X1056—Splice G12 BLK ( W9 ) X1057—Splice P37 RED ( W9 ) X1060—Splice G15 BLK ( W11 ) X1065—Splice L11 BRN ( W10 ) X1066—Splice L12 BRN ( W10 ) X1067—Splice G11 BLK ( W10 ) X1070—Splice G48 BLK ( W14 ) X1071—Splice L27 BRN ( W14 ) X1075—Splice G14 BLK ( W12 ) X1076—Splice R06 BLK ( W12 ) X1077—Splice P22 RED ( W12 ) X1078—Splice H03 GRN ( W12 ) X1079—Splice G11 BLK ( W12 ) X1080—Splice P20 RED ( W12 ) X1081—Splice R11 BLK ( W12 ) X1082—Splice P40 RED ( W12 ) X1083—Splice M03 YEL ( W12 ) X1084—Splice M04 GRN ( W12 ) X1085—Splice R62 BLK ( W12 ) X1086—Splice L04 BRN ( W12 ) X1087—Splice L11 BRN ( W12 ) X1088—Splice G11 BLK ( W12 ) <- Go to Section TOC
Section 9015 page 15
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
X1129—Splice WHT ( W16 ) X1130—Splice WHT ( W16 ) X1131—Splice WHT ( W16 ) X1150—Splice BLK ( W13 ) X1160—Splice 5437 PUR ( W21 ) X1161—Splice 5474 YEL ( W21 ) X1170—Splice P90 RED ( W24 ) X1171—Splice G51 BLK ( W24 ) X1175—Splice G51 BLK ( W25 ) X1225—Splice 5805C DK GRN ( W17 ) X1226—Splice 5804C YEL ( W17 ) X1227—Splice 5804D YEL ( W17 ) X1228—Splice 5805D DK GRN ( W17 ) X1229—Splice 5944 YEL ( W17 ) X1230—Splice 5774 YEL ( W17 ) X1231—Splice 5416 LT BLU ( W17 ) X1232—Splice 5805B DK GRN ( W17 ) X1233—Splice 5804B YEL ( W17 ) X1234—Splice 5805A DK GRN ( W17 ) X1235—Splice 5804A YEL ( W17 ) X1236—Splice 5441 BRN ( W17 ) X1237—Splice 5478 GRY ( W17 ) X1238—Splice 5410 BLK ( W17 ) X1239—Splice 5437 PUR ( W17 ) X1240—Splice 5446 LT BLU ( W17 ) X1250—Splice 5441 BRN ( W18 ) X1251—Splice 5478 GRY ( W18 ) X1252—Splice 5804 YEL ( W18 ) X1253—Splice 5805 GRN ( W18 ) X1254—Splice E04 WHT ( W18 ) X1255—Splice E05 WHT ( W18 ) X1256—Splice E06 WHT ( W18 ) X1257—Splice P09 RED ( W18 ) X1258—Splice M01 YEL ( W18 ) X1259—Splice M02 GRN ( W18 ) X1260—Splice R63 BLK ( W18 ) X1261—Splice 5410A BLK ( W18 ) X1262—Splice G17 BLK ( W18 ) X1263—Splice 5437 PUR ( W18 ) X1264—Splice 5474 YEL ( W18 ) X1265—Splice 5774 YEL ( W18 ) X1266—Splice 5410B BLK ( W18 ) X1300—Splice P82 RED ( W3 ) X1301—Splice G43 BLK ( W3 ) X1302—Splice G05 BLK ( W3 ) X1303—Splice G42 BLK ( W3 ) X1304—Splice P50 RED ( W3 ) X1305—Splice R63 BLK ( W3 ) X1306—Splice M02 GRN ( W3 ) X1307—Splice M01 YEL ( W3 ) X1308—Splice R51 BLK ( W3 ) X1309—Splice A34 ORG ( W3 ) X1310—Splice B03 RED ( W3 ) X1311—Splice P58 RED ( W3 ) X1312—Splice P12 RED ( W3 ) X1313—Splice R62 BLK ( W3 ) X1314—Splice R63 BLK ( W3 ) X1315—Splice M01 YEL ( W3 ) X1316—Splice M02 GRN ( W3 ) X1317—Splice R63 BLK ( W3 ) X1318—Splice M01 YEL ( W3 ) <- Go to Section TOC
Section 9015 page 16
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
X1319—Splice M02 GRN ( W3 ) X1320—Splice R63 BLK ( W3 ) X1321—Splice P18 RED ( W3 ) X1322—Splice P67 RED ( W3 ) X1323—Splice P62 RED ( W3 ) X1324—Splice P57 RED ( W3 ) X1325—Splice H27 GRN ( W3 ) X1326—Splice R51 BLK ( W3 ) X1327—Splice R62 BLK ( W3 ) X1328—Splice M04 GRN ( W3 ) X1329—Splice M03 YEL ( W3 ) X1330—Splice H29 GRN ( W3 ) X1331—Splice P75 RED ( W3 ) X1332—Splice M01 YEL ( W3 ) X1333—Splice M02 GRN ( W3 ) X1334—Splice R63 BLK ( W3 ) X1335—Splice M01 YEL ( W3 ) X1336—Splice M02 GRN ( W3 ) X1337—Splice R63 BLK ( W3 ) X1338—Splice P54 RED ( W3 ) X1339—Splice H23 GRN ( W3 ) X1340—Splice L10 BRN ( W3 ) X1341—Splice L19 BRN ( W3 ) X1342—Splice H05 GRN ( W3 ) X1343—Splice L01 BRN ( W3 ) X1344—Splice R06 BLK ( W3 ) X1345—Splice M01 YEL ( W3 ) X1346—Splice M02 GRN ( W3 ) X1347—Splice R63 BLK ( W3 ) X1348—Splice M03 YEL ( W3 ) X1349—Splice M04 GRN ( W3 ) X1350—Splice R62 BLK ( W3 ) X1351—Splice G09 BLK ( W3 ) X1352—Splice L14 BRN ( W3 ) X1353—Splice A10 ORG ( W3 ) X1354—Splice P53 RED ( W3 ) X1355—Splice L05 BRN ( W3 ) X1356—Splice L15 BRN ( W3 ) X1357—Splice L28 BRN ( W3 ) X1358—Splice G34 BLK ( W3 ) X1359—Splice L25 BRN ( W3 ) X1360—Splice G48 BLK ( W3 ) X1370—Splice (transmission control harness) ( W4 ) X1371—Splice (transmission control harness) ( W4 ) X1372—Splice (clutch control harness) ( W5 ) X1373—Splice (clutch control harness) ( W5 ) X1500—Splice G10 BLK ( W6002 ) X1501—Splice P84 RED ( W6002 ) X5001—ECU Static Ground Connector ( W17 ) X5003—Engine Harness-to-Engine Oil Pressure Sensor Harness 12-Pin Connector ( SE39 ) ( W17 ), ( W19 ) X5013—Not Used ( W17 ) X5015—Engine Interface Harness-to-Engine Harness 40-Pin Connector ( SE41 ) ( W17 ), ( W18 ) X5016—Engine Interface Harness-to-Engine Harness 40-Pin Connector ( SE41 ) ( W17 ), ( W18 ) X5023—Engine Harness-to-Fuel Injectors 6-Pin Connector ( W17 ) X5024—Engine Harness-to-Fuel Injectors 8-Pin Connector ( W17 ) X5301 (B5301)—Engine Harness-to-Engine Crankshaft Sensor Harness 2-Pin Connector (marked as B5301) ( W17 ), ( W20 ) X6001—Cellular Antenna Connector X6002—GPS Antenna Connector X6005—Satellite Antenna Connector X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector ( W6002 ) <- Go to Section TOC
Section 9015 page 17
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
X6015—Satellite (SAT) Module Control Unit 48-Pin Connector ( W6002 ) X6016—Satellite Adapter Harness-to-Universal JDLink™ Harness 6-Pin Connector ( W6002 ) Y2—Axle Cooling Cut-Off Solenoid ( SE13 ) ( W9 ) Y6—Secondary Steering Test Solenoid (S.N. —XXXXXX) ( SE7 ) ( W9 ) Y7—Dump Body Heat Solenoid ( SE10 ) ( W8 ) Y8—Electronic Brake Valve Solenoid ( SE11 ) ( W9 ) Y9—Left Side Fan Speed Solenoid ( SE12 ) ( W18 ) Y11—Right Side Fan Cut-Off Solenoid ( SE12 ) ( W9 ) Y15—Ether Start Aid Solenoid ( SE38 ) ( W18 ) Y22—Air Conditioner Compressor Clutch ( SE28 ) ( W2 ) Y23—Dump Body Down Control Solenoid ( SE10 ) ( W9 ) Y24—Dump Body Up Control Solenoid ( SE10 ) ( W9 ) Y25—Load Holding Pilot Solenoid ( SE10 ) ( W9 ) Y26—Dump Body Reduction Solenoid ( SE10 ) ( W9 ) Y30—Dump Body Lever Detent Magnet ( SE10 ) ( W3 ) Y31—Electronic Unit Injector (EUI) Solenoid Cyl #1 (2 used) ( SE40 ) Y32—Electronic Unit Injector (EUI) Solenoid Cyl #2 (2 used) ( SE40 ) Y33—Electronic Unit Injector (EUI) Solenoid Cyl #3 (2 used) ( SE40 ) Y34—Electronic Unit Injector (EUI) Solenoid Cyl #4 (2 used) ( SE40 ) Y35—Electronic Unit Injector (EUI) Solenoid Cyl #5 (2 used) ( SE40 ) Y36—Electronic Unit Injector (EUI) Solenoid Cyl #6 (2 used) ( SE40 ) Y38—Right Strut Up Solenoid ( SE8 ) ( W9 ) Y39—Right Strut Down Solenoid ( SE8 ) ( W9 ) Y40—Left Strut Up Solenoid( SE8 ) ( W9 ) Y41—Left Strut Down Solenoid ( SE8 ) ( W9 ) Y45—Park Brake Release Solenoid 2 ( SE11 ) ( W11 ) Y46—Park Brake Release Solenoid 1 ( SE11 ) ( W11 ) Y47—Coolant Heater Fuel Pump ( SE3 ) ( W24 ) Y48—Left Side Fan Low-Pressure Solenoid ( SE12 ) ( W2 ) Y49—Right Side Fan Low-Pressure Solenoid ( SE12 ) ( W2 ) Y50—Left Side Reversing Fan Solenoid ( SE12 ) ( W2 ) Y51—Right Side Reversing Fan Solenoid ( SE12 , SE13 ) ( W2 ) Y52—Front Axle Differential Lock Apply Solenoid ( SE13 ) ( W2 ) Y53—Middle Axle Differential Lock Apply Solenoid ( SE14 ) ( W12 ) Y54—Rear Axle Differential Lock Apply Solenoid ( SE15 ) ( W12 ) Y55—Front Axle Differential Lock Pressure Regulating Solenoid ( SE13 ) ( W2 ) Y56—Middle Axle Differential Lock Pressure Regulating Solenoid ( SE14 ) ( W12 ) Y57—Rear Axle Differential Lock Pressure Regulating Solenoid ( SE15 ) ( W12 ) Y60—Transmission Clutch A Solenoid ( SE5 ) ( W5 ) Y61—Transmission Clutch B Solenoid ( SE6 ) ( W5 ) Y62—Transmission Clutch C Solenoid ( SE6 ) ( W5 ) Y63—Transmission Clutch D Solenoid ( SE5 ) ( W5 ) Y64—Transmission Clutch E Solenoid ( SE6 ) ( W6 ) Y65—Transmission Clutch F Solenoid ( SE6 ) ( W5 ) Y66—Transmission Clutch R Solenoid ( SE6 ) ( W5 ) Y67—Transmission Clutch V Solenoid ( SE13 ) ( SE6 ) ( W6 ) Y68—Torque Converter Lockup (WK) Solenoid ( SE6 ) ( W6 ) Y69—Retarder Solenoid ( SE6 ) ( W6 ) Y70—Inter-Axle Differential Lock (IDL) Solenoid ( SE6 ) ( W5 ) Y71—Right Side Fan Speed Solenoid ( SE12 ) ( W9 ) Y5000—Fuel Dosing Shutoff Valve ( SE42 ) ( W17 ) Y5001—Fuel Dosing Control Valve ( SE42 ) ( W17 ) Y5400—Exhaust Gas Recirculation (EGR) Valve ( SE39 ) ( W17 ) Y5401—Intake Air Throttle( SE39 ) ( W17 ) Y5500—Variable Geometry Turbo (VGT) Actuator ( SE37 ) ( W17 ) Y5501—Low-Pressure Fuel Pump ( SE37 ) ( W18 ) Y5502—Fuel Dosing Pump ( SE37 ) ( W17 )
<- Go to Section TOC
Section 9015 page 18
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
System Functional Schematic and Section Legend SE1—Main Power and Start Circuits SE2—Charge, Interior Light, 15-Button SSM, and 25-Button SSM Circuits SE3—CAN Monitor Unit (CMU) and Coolant Heater Circuits SE4— Service ADVISOR ™ Diagnostic Connector Circuit SE5—Transmission Control Unit (TCU) Circuit SE6—Transmission Valve Control Module Circuit SE7—Chassis Control Unit (CCU) Power and Ground, Secondary Steering, and Fuel Level Sensor Circuits SE8—Suspension Height Control Circuits SE9—Stairwell and Service Lights Circuits SE10—Dump Body Control Circuits SE11—Park Brake, Electronic Brake Valve, Hydraulic Restriction, Hydraulic Temperature, and Articulation Angle Sensor Circuits SE12—Fan Control Circuits SE13—Front Axle Differential Circuits SE14—Middle Axle Differential Circuits SE15—Rear Axle Differential Circuits SE16—Seat Air Compressor and Heater Circuits SE17—Rear View Camera and Auto Greaser Circuits SE18—Work Lights and Articulation Backup Lights Circuits SE19—Headlights, Front Turn Lights, and Horn Circuits SE20—Steering Column Switch Circuits SE21—Rotating Beacon, Service Brake Lights, Tail Lights, Turn Lights, Backup Lights, and Backup Alarm Circuits SE22—Rear Window Wiper and Washer Circuits SE23—Front Windshield Wiper and Washer Circuits SE24—Mirror Defrost and Mirror Positioning Circuits SE25—24V to 12V DC Converter Circuit SE26—AM/FM Radio, Lighter, and 12-Volt Power Outlet Circuits SE27—Ground Speed Radar Circuit SE28—Air Conditioner High/Low Pressure Switch and Compressor Clutch Circuits SE29—Air Conditioner Sensor Circuits SE30—Heating and Air Conditioning Control Circuits SE31—On Board Weighing (OBW) Lights Circuits SE32—On Board Weighing (OBW) Controller Circuit SE33—Tire Pressure Monitoring (TPM) System Circuit SE34— JDLink ™ Circuit SE35—JDLink™ Circuit, Engine Control Unit (ECU) Power, and ECU CAN Circuits SE36—ECU Ground, Engine Coolant Loss Switches, Accelerator Pedal Sensor, and Ether Start Aid Circuits SE37—Engine Control Unit (ECU) Circuits SE38—Engine Control Unit (ECU) Circuits SE39—Engine Control Unit (ECU) Circuits SE40—Engine Control Unit (ECU) Circuits SE41—Engine Control Unit (ECU) Circuits SE42—Engine Control Unit (ECU) Circuits
<- Go to Section TOC
Section 9015 page 19
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
SE1—SE3
<- Go to Section TOC
Section 9015 page 20
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Section 9015 - ELECTRICAL SYSTEM
LEGEND: A1 A2 A7 A15 E9 E13 F1 F8 F22 F44 F46 F50 F51 G1 G3 H22 K1 K2 M1 S1 V1 V2 V3 W30 W31 W32 W36 W37 X7 X15 X29 X30 X50 X51 Y47
Group 10: System Diagrams
15-Button Sealed Switch Module (SSM) (OC4) 25-Button Sealed Switch Module (SSM) (OC3) CAN Monitor Unit (CMU) Coolant Heater Control Module (if equipped) Interior Light Coolant Heater Unit (if equipped) 25-Button SSM and Interior Light 10-Amp Fuse CMU Unswitched Power 10-Amp Fuse CMU and 15-Button SSM Switched Power 5-Amp Fuse Coolant Heater Control 15-Amp Fuse (inline) (if equipped) Coolant Heater Module 5-Amp Fuse (inline) (if equipped) Main 60-Amp Circuit Breaker Fuel Filter Heater 20-Amp Circuit Breaker Battery (2 used) Alternator Buzzer Ignition Relay Starter Relay Starter Motor Battery Disconnect Switch Ignition Relay Diode Starter Relay Diode Starter Motor Diode Engine Interface Harness Ground Cab Ground Starter Motor Ground Machine Frame-to-Cab Frame Ground Cable Engine Block-to-Machine Frame Ground Strap Coolant Heater Control Module Harness-to-Coolant Heat Unit Harness 4-Pin Connector Cab Harness-to-Front Frame Harness 9-Pin Connector Fuse Block Unswitched Power Terminal Fuse Block Switched Power Terminal Remote Battery Positive Charge Post Remote Battery Negative Charge Post Coolant Heater Fuel Pump (if equipped)
<- Go to Section TOC
Section 9015 page 21
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
SE4—SE6
<- Go to Section TOC
Section 9015 page 22
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Section 9015 - ELECTRICAL SYSTEM
LEGEND: A5 B17 B38 B39 B40 B41 B42 B43 F11 F12 F25 R3 R7 W31 W34 X9 X19 X40 X70 X71 X72 X73 X74 Y60 Y61 Y62 Y63 Y64 Y65 Y66 Y67 Y68 Y69 Y70
Group 10: System Diagrams
Transmission Control Unit (TCU) Transmission Filter Restriction Switch Retarder Temperature Sensor Transmission Sump Temperature Sensor Turbine Speed Sensor Clutch A Primary Speed Sensor Clutch C Secondary Speed Sensor Output Speed Sensor TCU Unswitched Power 10-Amp Fuse Service ADVISOR ™ Diagnostic Connector 10-Amp Fuse TCU Switched Power 10-Amp Fuse Cab Harness CAN 2 Termination Resistor Cab Harness CAN 1 Termination Resistor Cab Ground Hydraulic Harness Ground Cab Harness-to-Hydraulic Harness 31-Pin Connector Hydraulic Harness-to-Transmission Control Harness 2-Pin Connector Service ADVISOR™ Diagnostic 9-Pin Connector Transmission Control Unit (TCU) 21-Pin Connector Transmission Control Unit (TCU) 32-Pin Connector Transmission Control Harness-to-Clutch Control Harness 24-Pin Connector Clutch Control Harness-to-Retarder Control Harness 16-Pin Connector Retarder Control Harness-to-Output Speed Sensor 2-Pin Connector Clutch A Solenoid Clutch B Solenoid Clutch C Solenoid Clutch D Solenoid Clutch E Solenoid Clutch F Solenoid Clutch R Solenoid Clutch V Solenoid Torque Converter Lockup (WK) Solenoid Retarder Solenoid Inter-Axle Differential Lock (IDL) Solenoid
<- Go to Section TOC
Section 9015 page 23
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
SE7—SE9
<- Go to Section TOC
Section 9015 page 24
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A8 B10 B11 B12 B13 B37 E14 E19 E21 F5 F6 F7 F21 S4 S6 S7 W31 W33 W34 X8 X10 X14 X15 X21 X22 X23 X24 X45 Y6 Y38 Y39 Y40 Y41
<- Go to Section TOC
Group 10: System Diagrams
Chassis Control Unit (CCU) Right Side Height Sensor Left Side Height Sensor Hydraulic Pressure Sensor Secondary Steering Pressure Sensor Fuel Level Sensor Right Stairwell Light (if equipped) Left Stairwell Light Service Light Stairwell and Service Lights 10-Amp Fuse CCU VP2 Unswitched Power 10-Amp Fuse CCU VP3 Unswitched Power 20-Amp Fuse CCU VELX Switched Power 5-Amp Fuse Remote Stairwell Light Switch Service Light Switch Suspension Lowering Switch Cab Ground Front Frame Harness Ground Hydraulic Harness Ground Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Front Frame Harness 21-Pin Connector Cab Harness-to-Front Frame Harness 9-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Chassis Control Unit (CCU) 1-Pin Connector Cab Harness-to-Rear Work Light Harness 4-Pin Connector Secondary Steering Test Solenoid (S.N. —XXXXXX) Right Strut Up Solenoid Right Strut Down Solenoid Left Strut Up Solenoid Left Strut Down Solenoid
Section 9015 page 25
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
SE10—SE12
<- Go to Section TOC
Section 9015 page 26
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A8 B6 B7 B8 B9 B15 B16 B25 B26 B35 B54 V7 V8 V10 W31 W33 W34 X2 X3 X5 X8 X9 X10 X14 X16 X17 X21 X22 X23 Y7 Y8 Y9 Y11 Y23 Y24 Y25 Y26 Y30 Y45 Y46 Y48 Y49 Y50 Y51 Y71
Group 10: System Diagrams
Chassis Control Unit (CCU) Dump Body Position Sensor Left Fan Speed Sensor Right Fan Speed Sensor Hydraulic Filter Restriction Switch Park Brake Pressure Switch Dump Body Lock Switch Dump Body Lever Position Sensor Articulation Angle Sensor Brake Accumulator Low Pressure Switch Hydraulic Temperature Sensor Left Side Reversing Fan Solenoid Diode (if equipped) Right Side Reversing Fan Solenoid Diode (if equipped) Dump Body Lever Detent Magnet Diode Cab Ground Front Frame Harness Ground Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Hydraulic Harness-to-Hydraulic Tank Harness 6-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Front Frame Harness 21-Pin Connector Cab Harness-to-Engine Interface Harness 14-Pin Connector Rear Frame Harness-to-Rear Lights Harness 8-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Dump Body Heat Solenoid Electronic Brake Valve Solenoid Left Side Fan Speed Solenoid Right Side Fan Cut-Off Solenoid Dump Body Down Control Solenoid Dump Body Up Control Solenoid Load Holding Pilot Solenoid Dump Body Reduction Solenoid Dump Body Lever Detent Magnet Park Brake Release Solenoid 2 Park Brake Release Solenoid 1 Left Side Fan Low Pressure Solenoid Right Side Fan Low Pressure Solenoid Left Side Reversing Fan Solenoid (if equipped) Right Side Reversing Fan Solenoid (if equipped) Right Side Fan Speed Solenoid
<- Go to Section TOC
Section 9015 page 27
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
SE13—SE15
<- Go to Section TOC
Section 9015 page 28
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A8 B55 B58 B59 B60 B61 B62 B63 B64 B65 B67 B68 B69 S5 W33 W34 X2 X3 X8 X9 X10 X14 X21 X22 X23 Y2 Y52 Y53 Y54 Y55 Y56 Y57
Group 10: System Diagrams
Chassis Control Unit (CCU) Rear Axle Pressure Sensor Front Axle Differential Lock Pressure Sensor Middle Axle Differential Lock Pressure Sensor Rear Axle Differential Lock Pressure Sensor Front Axle Temperature Sensor Middle Axle Temperature Sensor Rear Axle Temperature Sensor Front Axle Pressure Sensor Middle Axle Pressure Sensor Front Axle Filter Restriction Switch Middle Axle Filter Restriction Switch Rear Axle Filter Restriction Switch Differential Lock Floor Switch Front Frame Harness Ground Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Front Frame Harness 21-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Axle Cooling Cut-Off Solenoid Front Axle Differential Lock Apply Solenoid Middle Axle Differential Lock Apply Solenoid Rear Axle Differential Lock Apply Solenoid Front Axle Differential Lock Pressure Regulating Solenoid Middle Axle Differential Lock Pressure Regulating Solenoid Rear Axle Differential Lock Regulating Solenoid
<- Go to Section TOC
Section 9015 page 29
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
SE16—SE18
<- Go to Section TOC
Section 9015 page 30
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A8 A9 A10 E17 E18 E28 E29 F26 F30 M11 R10 R14 R15 W31 W33 W34 X9 X21 X22 X23 X44 X45 X47 X48 X65 X66 X67
Group 10: System Diagrams
Chassis Control Unit (CCU) Rear View Monitor (if equipped) Rear View Camera (if equipped) Left Articulation Backup Light (if equipped) Right Articulation Backup Light (if equipped) Left Work Light Right Work Light Auto Greasing and Rear View Monitor 5-Amp Fuse Seat Compressor and Brake Accumulator Low Pressure Sensor 10-Amp Fuse Air Seat Compressor Fuel Filter Heater (if equipped) Seat Cushion Heater (if equipped) Back Cushion Heater (if equipped) Cab Ground Front Frame Harness Ground Hydraulic Harness Ground Cab Harness-to-Hydraulic Harness 31-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Cab Harness-to-Front Work Lights Harness 3-Pin Connector Cab Harness-to-Rear Work Lights Harness 4-Pin Connector Auto Greaser 6-Pin Connector Auto Greaser 6-Pin Connector Seat Heater 2-Pin Connector Seat Compressor 2-Pin Connector Rear View Camera Articulation 4-Pin Connector
<- Go to Section TOC
Section 9015 page 31
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
SE19—SE21
<- Go to Section TOC
Section 9015 page 32
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A8 B3 B23 B24 E1 E2 E3 E4 E5 E6 E7 E8 E10 E11 E12 E15 E16 F3 F4 F17 H1 H21 S2 W31 W33 X2 X3 X8 X14 X17 X21 X22 X23
<- Go to Section TOC
Group 10: System Diagrams
Chassis Control Unit (CCU) Electric Horn EBS Brake Switch Service Brake Lights Switch Right Rear Turn Light Left Rear Turn Light Right Front Turn Light Right Low Beam Headlight Right High Beam Headlight Left Front Turn Light Left Low Beam Headlight Left High Beam Headlight Right Rear Brake/Tail Light Left Rear Brake/Tail Light License Plate Light Right Backup Light Left Backup Light Horn 10-Amp Fuse Brake Light Switch 10-Amp Fuse Headlights, Tail Lights, and Turn Lights 15-Amp Fuse Backup Alarm Rotating Beacon (if equipped) Steering Column Switch Cab Ground Front Frame Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Front Frame Harness 21-Pin Connector Rear Frame Harness-to-Rear Lights Harness 8-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3)
Section 9015 page 33
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
SE22—SE24
<- Go to Section TOC
Section 9015 page 34
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A8 F18 F19 M3 M5 M9 M10 M12 M13 R12 R13 S3 W31 W33 X14 X15 X21 X22 X23 X36 X37
<- Go to Section TOC
Group 10: System Diagrams
Chassis Control Unit (CCU) Wiper Motor 10-Amp Fuse Mirror Switch 10-Amp Fuse Front Windshield Wiper Motor Front Windshield Washer Pump Motor Left Mirror Servo Motors (if equipped) Right Mirror Servo Motors (if equipped) Rear Window Wiper Motor (if equipped) Rear Window Washer Pump Motor (if equipped) Left Mirror Defroster (if equipped) Right Mirror Defroster (if equipped) Mirror Positioning Switch (if equipped) Cab Ground Front Frame Harness Ground Cab Harness-to-Front Frame Harness 21-Pin Connector Cab Harness-to-Front Frame Harness 9-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Cab Harness-to-Left Mirror Harness 6-Pin Connector Cab Harness-to-Right Mirror Harness 6-Pin Connector
Section 9015 page 35
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
SE25—SE27
<- Go to Section TOC
Section 9015 page 36
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A4 A8 A12 B45 B46 F9 F10 F23 F31 F32 F33 F34 F35 F36 F37 R8 U1 W29 W31 X2 X3 X8 X22 X23 X34 X38 X41 X42 X55 X56
<- Go to Section TOC
Group 10: System Diagrams
Ground Speed Radar Unit Chassis Control Unit (CCU) AM/FM Radio Left Speaker Right Speaker 24V/12V Converter (15-Amp) Unswitched Power 15-Amp Fuse 24V/12V Converter (25-Amp) Unswitched Power 25-Amp Fuse 24/12V Converter Switched Power 10-Amp Fuse Lighter 10-Amp Fuse 2-Way Radio 10-Amp Fuse 24V/12V Converter Monitoring 10-Amp Fuse 12-Volt Power Outlet 10-Amp Fuse Radio Switched Power 10-Amp Fuse Ground Speed Radar 5-Amp Fuse AM/FM Radio Memory 5-Amp Fuse Lighter 24V to 12V DC Converter AM/FM Radio Antenna Cab Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) 12-Volt Power Outlet Cab Harness-to-AM/FM Radio Harness 3-Pin Connector Left 2-Way Radio 2-Pin Connector Right 2-Way Radio 2-Pin Connector 24V/12V Converter 6-Pin Connector 24V/12V Converter 4-Pin Connector
Section 9015 page 37
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
SE28—SE30
<- Go to Section TOC
Section 9015 page 38
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A8 A16 B27 B28 B29 B30 F20 M2 M4 M6 M7 M8 R11 V4 W33 W35 X14 X21 X22 X23 X32 X33 X46 X84 X85 Y22
Group 10: System Diagrams
Chassis Control Unit (CCU) Air Conditioner Control Unit Air Conditioner High/Low Pressure Switch Air Conditioner Freeze Control Switch Air Conditioner Evaporator Temperature Sensor Air Conditioner Evaporator Inlet Sensor Air Conditioner Unit (ACU) 10-Amp Fuse Heater Control Valve Actuator Blower Motor Recirculation Vent Actuator Defrost and Middle Vent Actuator Floor Vent Actuator Blower Motor Resistor/Thermofuse Air Conditioner Compressor Clutch Diode Front Frame Harness Ground Air Conditioner Ground Cab Harness-to-Front Frame Harness 21-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Air Conditioner High/Low Pressure Switch 1-Pin Connector (A) Air Conditioner High/Low Pressure Switch 1-Pin Connector (B) Cab Harness-to-Air Conditioner Actuator Harness 12-Pin Connector Air Conditioner Actuator Control Unit 8-Pin Connector Air Conditioner Actuator Control Unit 6-Pin Connector Air Conditioner Compressor Clutch
<- Go to Section TOC
Section 9015 page 39
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
SE31—SE33
<- Go to Section TOC
Section 9015 page 40
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A8 A18 A19 B4 B5 B48 B49 B50 B51 B52 B53 F24 H12 H13 H14 L3 R4 W28 W31 W34 X2 X3 X8 X21 X22 X25 X26 X27 X28
Group 10: System Diagrams
Chassis Control Unit (CCU) On Board Weighing (OBW) Controller Tire Pressure Monitoring (TPM) System Controller (if equipped) Left Strain Gauge Right Strain Gauge TPM System Sensor (right front) (if equipped) TPM System Sensor (right middle) (if equipped) TPM System Sensor (right rear) (if equipped) TPM System Sensor (left rear) (if equipped) TPM System Sensor (left middle) (if equipped) TPM System Sensor (left front) (if equipped) OBW and TPMS 10-Amp Fuse Dump Body Under-Loaded Light (yellow) Dump Body Fully-Loaded Light (green) Dump Body Over-Loaded Light (red) On Board Weighing (OBW) CAN Filter OBW/TPMS CAN 2 Termination Resistor Tire Pressure Monitoring (TPM) System Antenna Cab Ground Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Left On Board Weighing (OBW) Load Lights 4-Pin Connector Right On Board Weighing (OBW) Load Lights 4-Pin Connector Left Strain Gauge 4-Pin Connector Right Strain Gauge 4-Pin Connector
<- Go to Section TOC
Section 9015 page 41
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
SE34—SE36
<- Go to Section TOC
Section 9015 page 42
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A3 A6000 A6001 A6002 A6003 B18 B19 B20 F13 F14 F27 F28 F52 R1 W30 W31 X13 X14 X16 X31 X6001 X6002 X6005 X6014 X6015 X6016
<- Go to Section TOC
Group 10: System Diagrams
Engine Control Unit (ECU) Modular Telematics Gateway (MTG) GPS and Cellular Antenna Satellite (SAT) Modular Control Unit Satellite Antenna Accelerator Pedal Sensor Engine Coolant Loss Service Switch Engine Coolant Loss Alarm Switch JDLink ™ Unswitched Power 10-Amp Fuse ECU Unswitched Power 20-Amp Fuse JDLink™ Switched Power 5-Amp Fuse ECU Switched Power 5-Amp Fuse JDLink™ Return (ground) 5-Amp Fuse (inline) Engine Interface Harness CAN 1 Termination Resistor Engine Interface Harness Ground Cab Ground Engine Control Unit (ECU) 54-Pin Connector (A5503) Cab Harness-to-Front Frame Harness 21-Pin Connector Cab Harness-to-Engine Interface Harness 14-Pin Connector Cab Harness-to-JDLink™ Harness 12-Pin Connector Cellular Antenna Connector GPS Antenna Connector Satellite Antenna Connector Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector Satellite (SAT) Module Control Unit 48-Pin Connector Satellite Adapter Harness-to-Universal JDLink™ Harness 6-Pin Connector
Section 9015 page 43
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
SE37—SE39
<- Go to Section TOC
Section 9015 page 44
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A3 B5101 B5102 B5103 B5104 B5107 B5110 B5300 B5301 B5302 B5500 B5600 F15 F16 R2 W30 X11 X12 X16 X5003 X5015 X5016 Y15 Y5400 Y5401 Y5500 Y5501 Y5502
<- Go to Section TOC
Group 10: System Diagrams
Engine Control Unit (ECU) Engine Oil Pressure Sensor Exhaust Manifold Pressure Sensor Exhaust Gas Recirculation (EGR) Flow Sensor Intake Manifold Pressure Sensor High-Pressure Fuel Pressure Sensor Low-Pressure Fuel Pressure Sensor Variable Geometry Turbocharger (VGT) Speed Sensor Crankshaft Position Sensor Camshaft Position Sensor Intake Air Sensor Water-In-Fuel (WIF) Sensor Fuel Dosing Pump 15-Amp Fuse Low Pressure Fuel Pump 15-Amp Fuse Engine CAN Termination Resistor Engine Interface Harness Ground Engine Control Unit (ECU) Connector (A5501) Engine Control Unit (ECU) Connector (A5502) Cab Harness-to-Engine Harness 14-Pin Connector Engine Harness-to-Engine Oil Pressure Sensor 12-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Ether Start Aid Solenoid Exhaust Gas Recirculation (EGR) Valve Actuator Air Throttle Valve Actuator Variable Geometry Turbocharger (VGT) Actuator Low Pressure Fuel Pump Fuel Dosing Pump
Section 9015 page 45
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
SE40—SE42
<- Go to Section TOC
Section 9015 page 46
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A3 B5000 B5106 B5108 B5109 B5200 B5204 B5205 B5206 B5207 B5208 B5209 B5511 B5512 B5513 X11 X12 X20 X5001 X5015 X5016 X5023 X5024 Y31 Y32 Y33 Y34 Y35 Y36 Y5000 Y5001
Group 10: System Diagrams
Engine Control Unit (ECU) Fuel Dosing Inlet Sensor Fuel Dosing Outlet Pressure Sensor Engine Coolant Pressure Sensor Diesel Particulate Filter (DPF) Differential Pressure Sensor Fixed Turbocharger Compressor Outlet Temperature Sensor Exhaust Filter Temperature Module Charge Air Cooler Outlet Temperature Sensor Manifold Air Temperature (MAT) Sensor Exhaust Gas Recirculation (EGR) Temperature Sensor Engine Coolant Temperature Sensor Fuel Temperature Sensor Diesel Oxidation Catalyst (DOC) Inlet Temperature Sensor Diesel Oxidation Catalyst (DOC) Outlet Temperature Sensor Diesel Particulate Filter (DPF) Outlet Temperature Sensor Engine Control Unit (ECU) Connector (A5501) Engine Control Unit (ECU) Connector (A5502) Engine Interface Harness-to-Exhaust Aftertreatment Harness 6-Pin Connector Engine Control Unit (ECU) Static Ground Engine Interface Harness-to-Engine Harness 40-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Engine Harness-to-Electronic Unit Injector (EUI) Harness 6-Pin Connector Engine Harness-to-Electronic Unit Injector (EUI) Harness 8-Pin Connector Electronic Unit Injector (EUI) Solenoid (2 used) (cylinder 1) Electronic Unit Injector (EUI) Solenoid (2 used) (cylinder 2) Electronic Unit Injector (EUI) Solenoid (2 used) (cylinder 3) Electronic Unit Injector (EUI) Solenoid (2 used) (cylinder 4) Electronic Unit Injector (EUI) Solenoid (2 used) (cylinder 5) Electronic Unit Injector (EUI) Solenoid (2 used) (cylinder 6) Fuel Dosing Shutoff Valve Fuel Dosing Control Valve
<- Go to Section TOC
Section 9015 page 47
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Power and Ground Component Location
Power and Ground Component Location LEGEND: 1 2 3 4 5 6 7
Main 60-Amp Circuit Breaker-to-Remote Charge Positive (+) Post Cable Battery Disconnect Switch Cable-to-Remote Charge Negative (—) Post Cable Chassis Control Unit (CCU) Switched Power Cable Battery-to-Starter Cable Battery-to-Battery Cable Remote Charge Negative (—) Post-to-Battery Cable Starter-to-Remote Charge Positive (+) Post Cable
<- Go to Section TOC
Section 9015 page 48
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
A8 F50 M1 S1 W30 W31 W32 W33 W34 W35 W36 W37 W38 X30 X50 X51 X54
Group 10: System Diagrams
Chassis Control Unit (CCU) Main 60-Amp Circuit Breaker Starter Motor Battery Disconnect Switch Engine Interface Harness Ground Cab Ground Starter Motor Ground Front Frame Harness Ground Hydraulic Harness Ground Air Conditioner Unit Ground Machine Frame-to-Cab Frame Ground Cable Engine Block-to-Machine Frame Ground Strap Cab Frame Ground Fuse Block Switched Power Terminal Remote Charge Positive (+) Post Remote Charge Negative (—) Post Fuse Block
<- Go to Section TOC
Section 9015 page 49
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Front Frame Harness (W2) Component Location
Front Frame Harness (W2) Component Location
<- Go to Section TOC
Section 9015 page 50
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 1 B3 B7 B8 B37 B58 B61 B64 B67 E3 E4 E5 E6 E7 E8 E21 F50 F51 F52 K1 M5 M13 R10 S1 S6 S7 V1 V4 W2 W33 X14 X15 Y22 Y48 Y49 Y50 Y51 Y52 Y55
<- Go to Section TOC
Group 10: System Diagrams
Rear View Electric Horn Left Fan Speed Sensor Right Fan Speed Sensor Fuel Level Sensor Front Axle Differential Lock Pressure Sensor Front Axle Temperature Sensor Front Axle Pressure Sensor Front Axle Filter Restriction Switch Right Front Turn Light Right Low Beam Headlight Right High Beam Headlight Left Front Turn Light Left Low Beam Headlight Left High Beam Headlight Service Light Main 60-Amp Circuit Breaker Fuel Filter Heater 20-Amp Circuit Breaker JDLink ™ Return (Ground) 5-Amp Fuse (inline) Ignition Relay Front Windshield Washer Pump Motor Rear Window Washer Pump Motor Fuel Filter Heater Battery Disconnect Switch Service Light Switch Remote Suspension Lowering Switch Ignition Relay Diode Air Conditioner Compressor Clutch Diode Front Frame Harness Engine Harness Ground (Main) Cab Harness-to-Front Frame Harness 21-Pin Connector Cab Harness-to-Front Frame Harness 9-Pin Connector Air Conditioner Compressor Clutch Left Side Fan Low Pressure Solenoid Right Side Fan Low Pressure Solenoid Left Side Reversing Fan Solenoid Right Side Reversing Fan Solenoid Front Axle Differential Lock Apply Solenoid Front Axle Differential Lock Pressure Regulating Solenoid
Section 9015 page 51
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Front Frame Harness (W2) Wiring Diagram
<- Go to Section TOC
Section 9015 page 52
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Front Frame Harness (W2) Wiring Diagram (1 of 2)
<- Go to Section TOC
Section 9015 page 53
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 1 2 B7 B37 E6 E7 E8 E21 S1 W33 X14 X15 X1000 X1001 X1002 X1003 X1004 Y48 Y50
<- Go to Section TOC
Group 10: System Diagrams
Continued on Sheet 2 of 2 Continued on Sheet 2 of 2 Left Fan Speed Sensor Fuel Level Sensor Left Front Turn Light Left Low Beam Headlight Left High Beam Headlight Service Light Battery Disconnect Switch Engine Harness Ground (Main) Cab Harness-to-Front Frame Harness 21-Pin Connector Cab Harness-to-Front Frame Harness 9-Pin Connector Splice R51 BLK Splice B03 RED Splice A34 ORG Splice H05 GRN Splice L01 BRN Left Side Fan Low Pressure Solenoid Left Side Reversing Fan Solenoid
Section 9015 page 54
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Front Frame Harness (W2) Wiring Diagram (2 of 2)
<- Go to Section TOC
Section 9015 page 55
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 1 2 B3 B8 B58 B61 B64 B67 E3 E4 E5 F50 F51 F52 K1 M5 M13 R10 S6 S7 V1 V4 X1005 X1006 X1007 X1008 X1009 X1010 Y22 Y49 Y51 Y52 Y55
<- Go to Section TOC
Group 10: System Diagrams
Continued on Sheet 1 of 2 Continued on Sheet 1 of 2 Electric Horn Right Fan Speed Sensor Front Axle Differential Lock Pressure Sensor Front Axle Temperature Sensor Front Axle Pressure Sensor Front Axle Filter Restriction Switch Right Front Turn Light Right Low Beam Headlight Right High Beam Headlight Main 60-Amp Circuit Breaker Fuel Filter Heater 20-Amp Circuit Breaker JDLink ™ Return (Ground) 5-Amp Fuse (inline) Ignition Relay Front Windshield Washer Pump Motor Rear Window Washer Pump Motor Fuel Filter Heater Service Light Switch Remote Suspension Lowering Switch Ignition Relay Diode Air Conditioner Compressor Clutch Diode Splice P18 RED Splice H14 GRN Splice R51 BLK Splice P50 RED Splice L06 BRN Splice L13 BRN Air Conditioner Compressor Clutch Right Side Fan Low Pressure Solenoid Right Side Reversing Fan Solenoid Front Axle Differential Lock Apply Solenoid Front Axle Differential Lock Pressure Regulating Solenoid
Section 9015 page 56
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Cab Harness (W3) Component Location
Cab Harness (W3) Component Location (1 of 2) LEGEND: A8 H12 H13 H14 <- Go to Section TOC
Chassis Control Unit (CCU) Left Dump Body Under-Loaded Light (yellow) Left Dump Body Fully-Loaded Light (green) Left Dump Body Over-Loaded Light (red) Section 9015 page 57
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
E9 E19 H21 R3 U1 W3 X21 X22 X23 X24 X25 X26 X29 X30 X31 X34 X36 X37 X40 X44 X45 X54 X55 X56 X65 X66
<- Go to Section TOC
Group 10: System Diagrams
Interior Light Left Stairwell Light Rotating Beacon (if equipped) Cab CAN 2 Termination Resistor 24V to12V DC Converter Cab Harness Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Chassis Control Unit (CCU) 1-Pin Connector Left OBW Load Lights 4-Pin Connector Right OBW Load Lights 4-Pin Connector Fuse Block Unswitched Power Terminal Fuse Block Switched Power Terminal Cab Harness-to-JDLink™ Harness 12-Pin Connector 12-Volt Power Outlet Cab Harness-to-Left Mirror Harness 6-Pin Connector Cab Harness-to-Right Mirror Harness 6-Pin Connector Service ADVISOR™ Diagnostic 9-Pin Connector Cab Harness-to-Front Work Lights Harness 3-Pin Connector Cab Harness-to-Rear Work Light Harness 4-Pin Connector Fuse Block 24v to 12V DC Converter 6-Pin Connector 24v to 12V DC Converter 4-Pin Connector Seat Heater 2-Pin Connector Seat Compressor 2-Pin Connector
Section 9015 page 58
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Cab Harness (W3) Component Location (2 of 2) LEGEND: 1 A1 A2 A7 A9 B18 <- Go to Section TOC
Right-Side View 15-Button Sealed Switch Module (SSM) (OC4) 25-Button Sealed Switch Module (SSM) (OC3) CAN Monitor Unit (CMU) Rear View Monitor (if equipped) Accelerator Pedal Position Sensor Section 9015 page 59
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
B25 B27 H22 M3 M12 R8 S2 S3 V10 W3 W31 W35 X8 X9 X10 X14 X15 X16 X34 X38 X40 X41 X42 X46 X47 X49 (B23, B24) X66 Y30
<- Go to Section TOC
Group 10: System Diagrams
Dump Body Lever Position Sensor Air Conditioner High/Low Pressure Switch Buzzer Front Windshield Wiper Motor Rear Windshield Wiper Motor Lighter Steering Column Switch Side Mirrors Positioning Switch Dump Body Lever Detent Magnet Diode Cab Harness Cab Ground Air Conditioner Unit Ground Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Front Frame Harness 21-Pin Connector Cab Harness-to-Front Frame Harness 9-Pin Connector Cab Harness-to-Engine Interface Harness 14-Pin Connector 12-Volt Power Outlet Cab Harness-to-AM/FM Radio Harness 3-pin Connector Service ADVISOR™ Diagnostic 9-Pin Connector Left 2-Way Radio 2-Pin Connector Right 2-Way Radio 2-Pin Connector Cab Harness-to-Air Conditioner Control Unit Harness 12-Pin Connector Auto Greaser 6-Pin Connector Brake Switch 4-Pin Connector (marked as B24) Seat Compressor 2-Pin Connector Dump Body Lever Detent Magnet
Section 9015 page 60
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Cab Harness (W3) Wiring Diagram
<- Go to Section TOC
Section 9015 page 61
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Cab Harness (W3) Wiring Diagram (1 of 5)
<- Go to Section TOC
Section 9015 page 62
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
<- Go to Section TOC
Group 10: System Diagrams
Section 9015 page 63
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Cab Harness (W3) Wiring Diagram (2 of 5)
<- Go to Section TOC
Section 9015 page 64
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 1 2 3 A1 A2 A9 B18 B25 M12 R8 S3 V10 W31 X8 X9 X10 X14 X15 X16 X42 X47 X49 (B23, B24) X1300 X1301 X1302 X1304 X1305 X1306 X1307 X1308 X1309 X1310 X1311 X1312 X1313 X1314 X1315 X1316 X1317 X1318 X1319 X1320 Y30
<- Go to Section TOC
Group 10: System Diagrams
Continued on Sheet 3 of 5 Continued on Sheet 3 of 5 Continued on Sheet 3 of 5 15-Button Sealed Switch Module (SSM) (OC4) 25-Button Sealed Switch Module (SSM) (OC3) Rear View Monitor (if equipped) Accelerator Pedal Position Sensor Dump Body Lever Position Sensor Rear Window Wiper Motor Lighter Side Mirrors Positioning Switch Dump Body Lever Detent Magnet Diode Cab Ground Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Front Frame Harness 21-Pin Connector Cab Harness-to-Front Frame Harness 9-Pin Connector Cab Harness-to-Engine Interface Harness 14-Pin Connector Right 2-Way Radio 2-Pin Connector Auto Greaser 6-Pin Connector Brake Switch 4-Pin Connector (marked as B24) Splice P82 RED Splice G43 BLK Splice G05 BLK Splice P50 RED Splice R63 BLK Splice M02 GRN Splice M01 YEL Splice R51 BLK Splice A34 ORG Splice B03 RED Splice P58 RED Splice P12 RED Splice R62 BLK Splice R63 BLK Splice M01 YEL Splice M02 GRN Splice R63 BLK Splice M01 YEL Splice M02 GRN Splice R63 BLK Dump Body Lever Detent Magnet
Section 9015 page 65
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Cab Harness (W3) Wiring Diagram (3 of 5)
<- Go to Section TOC
Section 9015 page 66
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 1 2 3 4 A7 B27 H22 M3 S2 W35 X32 (B27) X33 (B27) X34 X38 X40 X41 X46 X60 X65 X66 X1303 X1321 X1322 X1323 X1324 X1325 X1326 X1327 X1328 X1329 X1330 X1331 X1332 X1333 X1334 X1335 X1336 X1337 X1338
<- Go to Section TOC
Group 10: System Diagrams
Continued on Sheet 2 of 5 Continued on Sheet 2 of 5 Continued on Sheet 2 of 5 Continued on Sheet 4 of 5 CAN Monitor Unit (CMU) Air Conditioner High/Low Pressure Switch Buzzer Front Windshield Wiper Motor Steering Column Switch Air Conditioner Unit Ground Air Conditioner High/Low Pressure Switch 1-Pin Connector Air Conditioner High/Low Pressure Switch 1-Pin Connector 12-Volt Power Outlet Cab Harness-to-AM/FM Radio Harness 3-pin Connector Service ADVISOR™ Diagnostic 9-Pin Connector Left 2-Way Radio 2-Pin Connector Cab Harness-to-Air Conditioner Control Unit Harness 12-Pin Connector ZF CAN 2-Pin Connector Seat Heater 2-Pin Connector Seat Compressor 2-Pin Connector Splice G42 BLK Splice P18 RED Splice P67 RED Splice P62 RED Splice P57 RED Splice H27 GRN Splice R51 BLK Splice R62 BLK Splice M04 GRN Splice M03 YEL Splice H29 GRN Splice P75 RED Splice M01 YEL Splice M02 GRN Splice R63 BLK Splice M01 YEL Splice M02 GRN Splice R63 BLK Splice P54 RED
Section 9015 page 67
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Cab Harness (W3) Wiring Diagram (4 of 5)
<- Go to Section TOC
Section 9015 page 68
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 4 5 R3 X21 X22 X23 X29 X30 X31 X54 X55 X56 X1339 X1340 X1341 X1342 X1343 X1344 X1345 X1346 X1347 X1348 X1349 X1350 X1351 X1352
<- Go to Section TOC
Group 10: System Diagrams
Continued on Sheet 3 of 5 Continued on Sheet 5 of 5 Cab CAN 2 Termination Resistor Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Unswitched Power Terminal Fuse Block Switched Power Terminal Cab Harness-to-JDLink™ Harness 12-Pin Connector Fuse Block 24v to 12V DC Converter 6-Pin Connector 24v to 12V DC Converter 4-Pin Connector Splice H23 GRN Splice L10 BRN Splice L19 BRN Splice H05 GRN Splice L01 BRN Splice R06 BLK Splice M01 YEL Splice M02 GRN Splice R63 BLK Splice M03 YEL Splice M04 GRN Splice R62 BLK Splice G09 BLK Splice L14 BRN
Section 9015 page 69
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Cab Harness (W3) Wiring Diagram (5 of 5)
<- Go to Section TOC
Section 9015 page 70
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 5 E9 E19 H21 X25 X26 X36 X37 X44 X45 X1353 X1354 X1355 X1356 X1357 X1358 X1359 X1360
<- Go to Section TOC
Group 10: System Diagrams
Continued on Sheet 4 of 5 Interior Light Left Stairwell Light Rotating Beacon (if equipped) Left OBW Load Lights 4-Pin Connector Right OBW Load Lights 4-Pin Connector Cab Harness-to-Left Mirror Harness 6-Pin Connector Cab Harness-to-Right Mirror Harness 6-Pin Connector Cab Harness-to-Front Work Lights Harness 3-Pin Connector Cab Harness-to-Rear Work Light Harness 4-Pin Connector Splice A10 ORG Splice P53 RED Splice L05 BRN Splice L15 BRN Splice L28 BRN Splice G34 BLK Splice L25 BRN Splice G48 BLK
Section 9015 page 71
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Transmission Control Harness (W4) Component Location
Transmission Control Harness (W4) Component Location LEGEND: A5 Transmission Control Unit (TCU) W4 Transmission Control Harness X19 Hydraulic Harness-to-Transmission Control Harness 2-Pin Connector X71 TCU-to-Transmission Control Harness Connector X72 Transmission Control Harness-to-Transmission Valve Control Harness Connector
<- Go to Section TOC
Section 9015 page 72
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Transmission Control Harness (W4) Wiring Diagram
Transmission Control Harness (W4) Wiring Diagram
<- Go to Section TOC
Section 9015 page 73
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: X19 X71 X72 X1370 X1371
<- Go to Section TOC
Group 10: System Diagrams
Hydraulic Harness-to-Transmission Control Harness 2-Pin Connector Transmission Control Unit (TCU) 32-Pin Connector Transmission Control Harness-to-Clutch Control Harness 24-Pin Connector Splice Splice
Section 9015 page 74
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Clutch Control Harness (W5) Component Location
Clutch Control Harness (W5) Component Location LEGEND: B40 B41 W5 X72
Turbine Speed Sensor Transmission Clutch A (primary step) Speed Sensor Clutch Control Harness Transmission Control Harness-to-Transmission Valve Control Harness Connector
<- Go to Section TOC
Section 9015 page 75
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
X73 Y60 Y61 Y62 Y63 Y65 Y66 Y70
Group 10: System Diagrams
Clutch Control Harness-to-Retarder Control Harness 16-Pin Connector Transmission Clutch A Solenoid Transmission Clutch B Solenoid Transmission Clutch C Solenoid Transmission Clutch D Solenoid Transmission Clutch F Solenoid Transmission Clutch R Solenoid Inter-Axle Differential Lock (IDL) Solenoid
<- Go to Section TOC
Section 9015 page 76
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Clutch Control Harness (W5) Wiring Diagram
Clutch Control Harness (W5) Wiring Diagram
<- Go to Section TOC
Section 9015 page 77
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: B40 B41 X72 X73 X1372 X1373 Y60 Y61 Y62 Y63 Y65 Y66 Y70
<- Go to Section TOC
Group 10: System Diagrams
Turbine Speed Sensor Clutch A Primary Speed Sensor Transmission Control Harness-to-Clutch Control Harness 24-Pin Connector Clutch Control Harness-to-Retarder Control Harness 16-Pin Connector Splice Splice Clutch A Solenoid Clutch B Solenoid Clutch C Solenoid Clutch D Solenoid Clutch F Solenoid Clutch R Solenoid Inter-Axle Differential Lock (IDL) Solenoid
Section 9015 page 78
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Retarder Control Harness (W6) Component Location
Retarder Control Harness (W6) Component Location LEGEND: B38 B39 B42 W6
Retarder Temperature Sensor Transmission Sump Temperature Sensor Transmission Clutch A (secondary step) Speed Sensor Retarder Control Harness
<- Go to Section TOC
Section 9015 page 79
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
X73 X74 Y64 Y67 Y68 Y69
Group 10: System Diagrams
Clutch Control Harness-to-Retarder Control Harness 16-Pin Connector Retarder Control Harnes-to-Output Speed Sensor Harness 2-Pin Connector Transmission Clutch E Solenoid Transmission Clutch V Solenoid Torque Converter Lockup Solenoid Retarder Solenoid
<- Go to Section TOC
Section 9015 page 80
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Retarder Control Harness (W6) Wiring Diagram
Retarder Control Harness (W6) Wiring Diagram
<- Go to Section TOC
Section 9015 page 81
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: B38 B39 B42 X73 X74 Y64 Y67 Y68 Y69
Group 10: System Diagrams
Retarder Temperature Sensor Transmission Sump Temperature Sensor Clutch C Secondary Speed Sensor Clutch Control Harness-to-Retarder Control Harness 16-Pin Connector Retarder Control Harness-to-Output Speed Sensor Harness 2-Pin Connector Clutch E Solenoid Clutch V Solenoid Torque Converter Lockup (WK) Solenoid Retarder Solenoid
<- Go to Section TOC
Section 9015 page 82
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Output Speed Sensor Harness (W7) Component Location
Output Speed Sensor Harness (W7) Component Location LEGEND: B43 W7 X74
Output Speed Sensor Output Speed Sensor Harness Retarder Control Harnes-to-Output Speed Sensor Harness 2-Pin Connector
<- Go to Section TOC
Section 9015 page 83
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Output Speed Sensor Harness (W7) Wiring Diagram
Output Speed Sensor Harness (W7) Wiring Diagram LEGEND: B43 X74
Output Speed Sensor Retarder Control Harness-to-Output Speed Sensor Harness 2-Pin Connector
<- Go to Section TOC
Section 9015 page 84
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Hydraulic Tank Harness (W8) Component Location
Hydraulic Tank Harness (W8) Component Location LEGEND: B9 B54 W8 X5 Y7
<- Go to Section TOC
Hydraulic Filter Restriction Switch Hydraulic Temperature Sensor Hydraulic Tank Harness Hydraulic Harness-to-Hydraulic Tank Harness 6-Pin Connector Dump Body Heat Solenoid
Section 9015 page 85
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Hydraulic Tank Harness (W8) Wiring Diagram
Hydraulic Tank Harness (W8) Wiring Diagram LEGEND: B9 B54 X5 Y7
Hydraulic Filter Restriction Switch Hydraulic Temperature Sensor Hydraulic Harness-to-Hydraulic Tank Harness 6-Pin Connector Dump Body Heat Solenoid
<- Go to Section TOC
Section 9015 page 86
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Hydraulic Harness (W9) Component Location
Hydraulic Harness (W9) Component Location
<- Go to Section TOC
Section 9015 page 87
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A5 B10 B11 B12 B13 B17 B26 B35 R7 S4 S5 W9 W34 X3 X5 X8 X9 X10 X19 X48 X70 Y2 Y6 Y8 Y11 Y23 Y24 Y25 Y26 Y38 Y39 Y40 Y41 Y71
Group 10: System Diagrams
Transmission Control Unit (TCU) Right Side Height Sensor Left Side Height Sensor Main Hydraulic Pressure Sensor Secondary Steering Pressure Sensor Transmission Filter Restriction Switch Articulation Angle Sensor Brake Accumulator Low Pressure Switch Hydraulic Harness CAN 1 Termination Resistor Remote Stairwell Light Switch Differential Lock Floor Switch Hydraulic Harness Hydraulic Harness Ground Hydraulic Harness-to-Articulation Harness 21-Pin Connector Hydraulic Harness-to-Hydraulic Tank Harness 6-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Hydraulic Harness-to-Transmission Control Harness 2-Pin Connector Auto Greaser 6-Pin Connector Hydraulic Harness Transmission Control Unit (TCU) Connector Axle Cooling Cut-Off Solenoid Secondary Steering Test Solenoid (S.N. —XXXXXX) Electronic Brake Valve Solenoid Right Side Fan Cut-Off Solenoid Dump Body Down Control Solenoid Dump Body Up Control Solenoid Load Holding Pilot Solenoid Dump Body Reduction Solenoid Right Strut Up Solenoid Right Strut Down Solenoid Left Strut Up Solenoid Left Strut Down Solenoid Right Side Fan Speed Solenoid
<- Go to Section TOC
Section 9015 page 88
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Hydraulic Harness (W9) Wiring Diagram
<- Go to Section TOC
Section 9015 page 89
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Hydraulic Harness (W9) Wiring Diagram (1 of 2)
<- Go to Section TOC
Section 9015 page 90
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 1 2 B11 B17 R7 S4 X3 X5 X19 X48 X70 X1053 X1054 X1055 X1056 X1057 Y23 Y24 Y25
<- Go to Section TOC
Group 10: System Diagrams
Continued on Sheet 2 of 2 Continued on Sheet 2 of 2 Left Side Height Sensor Transmission Filter Restriction Switch Hydraulic Harness CAN 1 Termination Resistor Remote Stairwell Light Switch Hydraulic Harness-to-Articulation Harness 21-Pin Connector Hydraulic Harness-to-Hydraulic Tank Harness 6-Pin Connector Hydraulic Harness-to-Transmission Control Harness 2-Pin Connector Auto Greaser 6-Pin Connector Hydraulic Harness Transmission Control Unit (TCU) Connector Splice M01 YEL Splice M02 GRN Splice M05 PUR Splice G12 BLK Splice P37 RED Dump Body Down Control Solenoid Dump Body Up Control Solenoid Load Holding Pilot Solenoid
Section 9015 page 91
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Hydraulic Harness (W9) Wiring Diagram (2 of 2)
<- Go to Section TOC
Section 9015 page 92
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 1 2 B10 B12 B13 B26 B35 S5 W34 X8 X9 X10 X1050 X1051 X1052 Y2 Y6 Y8 Y11 Y26 Y38 Y39 Y40 Y41 Y71
<- Go to Section TOC
Group 10: System Diagrams
Continued on Sheet 1 of 2 Continued on Sheet 1 of 2 Right Side Height Sensor Main Hydraulic Pressure Sensor Secondary Steering Pressure Sensor Articulation Angle Sensor Brake Accumulator Low Pressure Switch Differential Lock Floor Switch Hydraulic Harness Ground Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Splice R51 BLK Splice P51 RED Splice R37 BLK Axle Cooling Cut-Off Solenoid Secondary Steering Test Solenoid (S.N. —XXXXXX) Electronic Brake Valve Solenoid Right Side Fan Cut-Off Solenoid Dump Body Reduction Solenoid Right Strut Up Solenoid Right Strut Down Solenoid Left Strut Up Solenoid Left Strut Down Solenoid Right Side Fan Speed Control Solenoid
Section 9015 page 93
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Rear Lights Harness (W10) Component Location
Rear Lights Harness (W10) Component Location LEGEND: B16 E1 E2 E10 E11 W10 X17
<- Go to Section TOC
Dump Body Lock Sensor Right Rear Turn Light Left Rear Turn Light Right Rear Park/Brake Light Left Rear Park/Brake Light Rear Lights Harness Rear Frame Harness-to-Rear Lights Harness 8-Pin Connector
Section 9015 page 94
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Rear Lights Harness (W10) Wiring Diagram
Rear Lights Harness (W10) Wiring Diagram LEGEND: B16 E1 E2 E10 E11 X17 X1065 X1066 X1067
<- Go to Section TOC
Dump Body Lock Sensor Right Rear Turn Light Left Rear Turn Light Right Rear Park/Brake Light Left Rear Park/Brake Light Rear Frame Harness-to-Rear Lights Harness 8-Pin Connector Splice L11 BRN Splice L12 BRN Splice G11 BLK
Section 9015 page 95
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Articulation Harness (W11) Component Location
Articulation Harness (W11) Component Location LEGEND: 1 B15 W11 X2 X3 Y45 Y46
<- Go to Section TOC
Detail View (Right rear view) Park Brake Pressure Switch Articulation Harness Articulation Harness-to-Rear Frame Harness Hydraulic Harness-to-Articulation Harness 21-Pin Connector Park Brake Release Solenoid 2 Park Brake Release Solenoid 1
Section 9015 page 96
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Articulation Harness (W11) Wiring Diagram
Articulation Harness (W11) Wiring Diagram LEGEND: B15 X2 X3 X1060 Y45 Y46
<- Go to Section TOC
Park Brake Pressure Switch Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Splice G15 BLK Park Brake Release Solenoid 2 Park Brake Release Solenoid 1
Section 9015 page 97
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Rear Frame Harness (W12) Component Location
Rear Frame Harness (W12) Component Location LEGEND: A4 A18 A19 B4 B5 B6 B49 B55 B59 B60 B62 B63 B65 B68
Ground Speed Radar Unit On Board Weighing (OBW) Controller Tire Pressure Monitoring (TPM) System Controller Left OBW Strain Gauge Right OBW Strain Gauge Dump Body Position Sensor Tire Pressure Monitoring (TPM) System Sensor (6 used, if equipped) Rear Axle Pressure Sensor Middle Axle Differential Lock Pressure Sensor Rear Axle Differential Lock Pressure Sensor Middle Axle Temperature Sensor Rear Axle Temperature Sensor Middle Axle Pressure Sensor Middle Axle Filter Restriction Switch
<- Go to Section TOC
Section 9015 page 98
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
B69 E12 E15 E16 H1 R4 W12 X2 X17 X27 X28 Y53 Y54 Y56 Y57
Group 10: System Diagrams
Rear Axle Filter Restriction Switch License Plate Light (if equipped) Right Backup Light Left Backup Light Backup Alarm OBW/TPMS CAN 2 Termination Resistor Rear Frame Harness Articulation Harness-to-Rear Frame Harness 21-Pin Connector Rear Frame Harness-to-Rear Lights Harness 8-Pin Connector Left Strain Gauge 4-Pin Connector Right Strain Gauge 4-Pin Connector Middle Axle Differential Lock Apply Solenoid Rear Axle Differential Lock Apply Solenoid Middle Axle Differential Lock Pressure Regulating Solenoid Rear Axle Differential Lock Pressure Regulating Solenoid
<- Go to Section TOC
Section 9015 page 99
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Rear Frame Harness (W12) Wiring Diagram
<- Go to Section TOC
Section 9015 page 100
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Rear Frame Harness (W12) Wiring Diagram (1 of 2)
<- Go to Section TOC
Section 9015 page 101
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 1 A4 B55 B59 B60 B62 B63 B65 B68 B69 X2 X1075 X1076 X1077 X1078 Y53 Y54 Y56 Y57
<- Go to Section TOC
Group 10: System Diagrams
Continued on Sheet 2 of 2 Ground Speed Radar Unit Rear Axle Pressure Sensor Middle Axle Differential Lock Pressure Sensor Rear Axle Differential Lock Pressure Sensor Middle Axle Temperature Sensor Rear Axle Temperature Sensor Middle Axle Pressure Sensor Middle Axle Filter Restriction Switch Rear Axle Filter Restriction Switch Articulation Harness-to-Rear Frame Harness 21-Pin Connector Splice G14 BLK Splice R06 BLK Splice P22 RED Splice H03 GRN Middle Axle Differential Lock Apply Solenoid Rear Axle Differential Lock Apply Solenoid Middle Axle Differential Lock Pressure Regulating Solenoid Rear Axle Differential Lock Pressure Regulating Solenoid
Section 9015 page 102
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Rear Frame Harness (W12) Wiring Diagram (2 of 2)
<- Go to Section TOC
Section 9015 page 103
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 1 A18 A19 B6 E12 E15 E16 H1 R4 X17 X27 X28 X1079 X1080 X1081 X1082 X1083 X1084 X1085 X1086 X1087 X1088
<- Go to Section TOC
Group 10: System Diagrams
Continued on Sheet 1 of 2 On-Board Weighing (OBW) Controller Tire Pressure Monitoring (TPM) System Controller Dump Body Position Sensor License Plate Light (if equipped) Right Backup Ligh Left Backup Light Backup Alarm OBW/TPMS CAN 2 Termination Resistor Rear Frame Harness-to-Rear Lights Harness 8-Pin Connector Left Strain Gauge 4-Pin Connector Right Strain Gauge 4-Pin Connector Splice G11 BLK Splice P20 RED Splice R11 BLK Splice P40 RED Splice M03 YEL Splice M04 GRN Splice R62 BLK Splice L04 BRN Splice L11 BRN Splice G11 BLK
Section 9015 page 104
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Front Work Lights Harness (W13) Component Location
Front Work Lights Harness (W13) Component Location LEGEND: E28 E29 W13 X44
<- Go to Section TOC
Left Front Work Light Right Front Work Light Front Work Lights Harness Cab Harness-to-Front Work Lights Harness 3-Pin Connector
Section 9015 page 105
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Front Work Lights Harness (W13) Wiring Diagram
Front Work Lights Harness (W13) Wiring Diagram LEGEND: E28 E29 X44 X1150
<- Go to Section TOC
Left Front Work Light Right Front Work Light Cab Harness-to-Front Work Lights Harness 3-Pin Connector Splice BLK
Section 9015 page 106
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Rear Work Lights Harness (W14) Component Location
Rear Work Lights Harness (W14) Component Location LEGEND: E14 E17 E18 W14 X45
<- Go to Section TOC
Right Stairwell Light (if equipped) Left Articulation Backup Light Right Articulation Backup Light Rear Work Light Harness Cab Harness-to-Rear Work Light Harness 4-Pin Connector
Section 9015 page 107
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Rear Work Lights Harness (W14) Wiring Diagram
Rear Work Lights Harness (W14) Wiring Diagram LEGEND: E14 E17 E18 X45 X1070 X1071
<- Go to Section TOC
Right Stairwell Light (if equipped) Left Articulation Backup Light Right Articulation Backup Light Cab Harness-to-Rear Work Light Harness 4-Pin Connector Splice G48 BLK Splice L27 BRN
Section 9015 page 108
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
AM/FM Radio Harness (W15) Component Location
AM/FM Radio Harness (W15) Component Location LEGEND: A12 B45 B46 W13 W29 X38
<- Go to Section TOC
AM/FM Radio Left Speaker Right Speaker AM/FM Radio Harness AM/FM Radio Antenna Cab Harness-to-AM/FM Radio Harness 3-Pin Connector
Section 9015 page 109
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
AM/FM Radio Harness (W15) Wiring Diagram
AM/FM Radio Harness (W15) Wiring Diagram LEGEND: A12 B45 B46 X38
<- Go to Section TOC
AM/FM Radio Left Speaker Right Speaker Cab Harness-to-AM/FM Radio Harness 3-Pin Connector
Section 9015 page 110
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Air Conditioner Unit Harness (W16) Component Location
Air Conditioner Unit Harness (W16) Component Location (S.N. —664056) LEGEND: A16 B28 B29 B30 M2 M4 M6 M7 M8 R11 W35 X46
<- Go to Section TOC
Air Conditioner Unit Air Conditioner Freeze Control Switch Air Conditioner Evaporator Temperature Sensor Air Conditioner Evaporator Inlet Sensor Heater Control Valve Actuator Blower Motor Recirculation Vent Actuator Defrost and Middle Vent Actuator Floor Vent Actuator Blower Motor Resistor/Thermofuse Air Conditioner Ground Cab Harness-to-Air Conditioner Unit Harness 12-Pin Connector
Section 9015 page 111
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Air Conditioner Unit Harness (W16) Component Location (S.N. 664057— ) LEGEND: A16 B28 B29 B30 M2 M4 M6 M7 M8 R11 W35 X46
<- Go to Section TOC
Air Conditioner Unit Air Conditioner Freeze Control Switch Air Conditioner Evaporator Temperature Sensor Air Conditioner Evaporator Inlet Sensor Heater Control Valve Actuator Blower Motor Recirculation Vent Actuator Defrost and Middle Vent Actuator Floor Vent Actuator Blower Motor Resistor/Thermofuse Air Conditioner Ground Cab Harness-to-Air Conditioner Unit Harness 12-Pin Connector
Section 9015 page 112
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Air Conditioner Unit Harness (W16) Wiring Diagram
<- Go to Section TOC
Section 9015 page 113
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Air Conditioner Actuator Harness (W16) Wiring Diagram (S.N. — 664056)
<- Go to Section TOC
Section 9015 page 114
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A16 B28 B29 B30 M2 M4 M6 M7 M8 R11 W35 X46 X84 X85 X1129 X1130 X1131
<- Go to Section TOC
Group 10: System Diagrams
Air Conditioner Unit Air Conditioner Freeze Control Switch Air Conditioner Evaporator Temperature Sensor Air Conditioner Evaporator Inlet Sensor Heater Control Valve Actuator Blower Motor Recirculation Vent Actuator Defrost and Middle Vent Actuator Floor Vent Actuator Blower Motor Resistor/Thermofuse Air Conditioner Ground Cab Harness-to-Air Conditioner Unit Harness 12-Pin Connector Air Conditioner Unit 8-Pin Connector Air Conditioner Unit 6-Pin Connector Splice WHT Splice WHT Splice WHT
Section 9015 page 115
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Air Conditioner Actuator Harness (W16) Wiring Diagram (S.N. 664057— )
<- Go to Section TOC
Section 9015 page 116
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: A16 B28 B29 B30 M2 M4 M6 M7 M8 R11 W35 X46 X84 X85 X1129 X1130 X1131
<- Go to Section TOC
Group 10: System Diagrams
Air Conditioner Unit Air Conditioner Freeze Control Switch Air Conditioner Evaporator Temperature Sensor Air Conditioner Evaporator Inlet Sensor Heater Control Valve Actuator Blower Motor Recirculation Vent Actuator Defrost and Middle Vent Actuator Floor Vent Actuator Blower Motor Resistor/Thermofuse Air Conditioner Ground Cab Harness-to-Air Conditioner Unit Harness 12-Pin Connector Air Conditioner Unit 8-Pin Connector Air Conditioner Unit 6-Pin Connector Splice WHT Splice WHT Splice WHT
Section 9015 page 117
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Engine Harness (W17) Component Location
Engine Harness (W17) Component Location (left view) LEGEND: B5000 B5102 B5103 B5104 B5106 B5205 B5206 B5207 B5208 B5301 B5302 B5500 W17 W20 X5001 X5003 <- Go to Section TOC
Fuel Dosing Inlet Sensor Exhaust Manifold Pressure Sensor Exhaust Gas Recirculation (EGR) Flow Sensor Intake Manifold Pressure Sensor Fuel Dosing Outlet Pressure Sensor Charge Air Cooler Outlet Temperature Sensor Manifold Air Temperature Sensor Exhaust Gas Recirculation (EGR) Temperature Sensor Engine Coolant Temperature Sensor Crankshaft Position Sensor Camshaft Position Sensor Intake Air Sensor Engine Harness Engine Crankshaft Sensor Harness ECU Static Ground Connector Engine Harness-to-Engine Oil Pressure Sensor Harness 12-Pin Connector Section 9015 page 118
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
X5013 X5015 X5016 X5023 X5024 X5301 (B5301) Y5000 Y5001 Y5400 Y5401 Y5500 Y5502
Group 10: System Diagrams
Not Used Engine Interface Harness-to-Engine Harness 40-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Engine Harness-to-Fuel Injectors 6-Pin Connector Engine Harness-to-Fuel Injectors 8-Pin Connector Engine Harness-to-Engine Crankshaft Sensor Harness 2-Pin Connector Fuel Dosing Shutoff Valve Fuel Dosing Control Valve Exhaust Gas Recirculation (EGR) Valve Intake Air Throttle Variable Geometry Turbo (VGT) Actuator Fuel Dosing Pump
Engine Harness (W17) Component Location (right view) LEGEND: B5102 B5108 B5200 B5205 <- Go to Section TOC
Exhaust Manifold Pressure Sensor Engine Coolant Pressure Sensor Fixed Turbo Charger Compressor Outlet Temperature Sensor Charge Air Cooler Outlet Temperature Sensor Section 9015 page 119
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
B5208 B5300 B5500 W17 Y5400 Y5401 Y5500
<- Go to Section TOC
Group 10: System Diagrams
Engine Coolant Temperature Sensor Variable Geometry Turbo (VGT) Speed Sensor Intake Air Sensor Engine Harness Exhaust Gas Recirculation (EGR) Valve Intake Air Throttle Variable Geometry Turbo (VGT) Actuator
Section 9015 page 120
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Engine Harness (W17) Wiring Diagram
<- Go to Section TOC
Section 9015 page 121
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Engine Harness (W17) Wiring Diagram (1 of 2)
<- Go to Section TOC
Section 9015 page 122
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 1 B5102 B5104 B5108 B5200 B5208 B5300 B5500 R2 X1225 X1226 X1227 X1228 X1229 Y5401 Y5500
<- Go to Section TOC
Group 10: System Diagrams
Continued on Sheet 2 of 2 Exhaust Manifold Pressure Sensor Intake Manifold Pressure Sensor Engine Coolant Pressure Sensor Fixed Turbo Charger Compressor Outlet Temperature Sensor Engine Coolant Temperature Sensor Variable Geometry Turbo (VGT) Speed Sensor Intake Air Sensor Engine CAN Termination Resistor Splice 5805C DK GRN Splice 5804C YEL Splice 5804D YEL Splice 5805D DK GRN Splice 5944 YEL Intake Air Throttle Variable Geometry Turbo (VGT) Actuator
Section 9015 page 123
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Engine Harness (W17) Wiring Diagram (2 of 2)
<- Go to Section TOC
Section 9015 page 124
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
LEGEND: 1 B5000 B5103 B5106 B5205 B5206 B5207 B5302 X1230 X1231 X1232 X1233 X1234 X1235 X1236 X1237 X1238 X1239 X1240 X5001 X5003 X5013 X5015 X5016 X5023 X5024 X5301 (B5301) Y5000 Y5001 Y5400 Y5502
Continued on Sheet 1 of 2 Fuel Dosing Inlet Sensor Exhaust Gas Recirculation (EGR) Flow Sensor Fuel Dosing Outlet Pressure Sensor Charge Air Cooler Outlet Temperature Sensor Manifold Air Temperature Sensor Exhaust Gas Recirculation (EGR) Temperature Sensor Camshaft Position Sensor Splice 5774 YEL Splice 5416 LT BLU Splice 5805B DK GRN Splice 5804B YEL Splice 5805A DK GRN Splice 5804A YEL Splice 5441 BRN Splice 5478 GRY Splice 5410 BLK Splice 5437 PUR Splice 5446 LT BLU ECU Static Ground Connector Engine Harness-to-Engine Oil Pressure Sensor Harness 12-Pin Connector Not Used Engine Interface Harness-to-Engine Harness 40-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Engine Harness-to-Fuel Injectors 6-Pin Connector Engine Harness-to-Fuel Injectors 8-Pin Connector Engine Harness-to-Engine Crankshaft Sensor Harness 2-Pin Connector Fuel Dosing Shutoff Valve Fuel Dosing Control Valve Exhaust Gas Recirculation (EGR) Valve Fuel Dosing Pump
<- Go to Section TOC
Section 9015 page 125
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Engine Interface Harness (W18) Component Location
Engine Interface Harness (W18) Component Location LEGEND: 1 A3 B19 B20 B5107 B5110 B5209 B5600 G3 K2 M1 R1 V2 V3 <- Go to Section TOC
Detail (right top rear view) Engine Control Unit (ECU) Engine Coolant Loss Service Switch Engine Coolant Loss Alarm Switch High-Pressure Fuel Pressure Sensor Low-Pressure Fuel Pressure Sensor Fuel Temperature Sensor Water-in-Fuel (WIF) Sensor Alternator Stater Relay Starter Motor Engine Interface Harness CAN 1 Termination Resistor Starter Relay Diode Stater Solenoid Diode Section 9015 page 126
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
W30 X11 X12 X13 X16 X20 X5015 X5016 Y9 Y15 Y5501
<- Go to Section TOC
Group 10: System Diagrams
Engine Harness Ground (Main) Engine Control Unit (ECU) Connector 1 Engine Control Unit (ECU) Connector 2 Engine Control Unit (ECU) Connector 3 Cab Harness-to-Engine Interface Harness 14-Pin Connector Engine Interface Harness-to-Exhaust Aftertreatment Harness Engine Interface Harness-to-Engine Harness 40-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Left Side Fan Speed Solenoid Ether Start Aid Solenoid Low Pressure Fuel Pump
Section 9015 page 127
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Engine Interface Harness (W18) Wiring Diagram
<- Go to Section TOC
Section 9015 page 128
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Engine Interface Harness (W18) Wiring Diagram (1 of 3)
<- Go to Section TOC
Section 9015 page 129
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 1 B5107 B5110 B5209 B5600 X1250 X1251 X1252 X1253 Y5501
<- Go to Section TOC
Group 10: System Diagrams
Continued on Sheet 2 of 3 High-Pressure Fuel Pressure Sensor Low-Pressure Fuel Pressure Sensor Fuel Temperature Sensor Water-in-Fuel (WIF) Sensor Splice 5441 BRN Splice 5478 GRY Splice 5804 YEL Splice 5805 GRN Low Pressure Fuel Pump
Section 9015 page 130
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Engine Interface Harness (W18) Wiring Diagram (2 of 3)
<- Go to Section TOC
Section 9015 page 131
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 1 2 K2 R1 V2 V3 X11 X12 X13 X16 X20 X1254 X1255 X1256 X1257 X1258 X1259 X1260 X1261 X1262 X1263 X1264 X1265
<- Go to Section TOC
Group 10: System Diagrams
Continued on Sheet 1 of 3 Continued on Sheet 3 of 3 Starter Relay Engine Interface Harness CAN 1 Termination Resistor Starter Relay Diode Starter Solenoid Diode Engine Control Unit (ECU) Connector 1 Engine Control Unit (ECU) Connector 2 Engine Control Unit (ECU) Connector 3 Cab Harness-to-Engine Interface Harness 14-Pin Connector Engine Interface Harness-to-Exhaust Aftertreatment Harness 6-Pin Connector Splice E04 WHT Splice E05 WHT Splice E06 WHT Splice P09 RED Splice M01 YEL Splice M02 GRN Splice R63 BLK Splice 5410A BLK Splice G17 BLK Splice 5437 PUR Splice 5474 YEL Splice 5774 YEL
Section 9015 page 132
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Engine Interface Harness (W18) Wiring Diagram (3 of 3)
<- Go to Section TOC
Section 9015 page 133
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
LEGEND: 2 B19 B20 G3 M1 W30 X1266 X5015 X5016 Y9 Y15
<- Go to Section TOC
Group 10: System Diagrams
Continued on Sheet 2 of 3 Engine Coolant Loss Service Switch Engine Coolant Loss Alarm Switch Alternator Starter Motor Engine Harness Ground (Main) Splice 5410B BLK Engine Interface Harness-to-Engine Harness 40-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Left Side Fan Speed Solenoid Ether Start Aid Solenoid
Section 9015 page 134
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Engine Oil Pressure Sensor Harness (W19) Component Location
Engine Oil Pressure Sensor Harness (W19) Component Location LEGEND: B5101 W19 X5003
<- Go to Section TOC
Engine Oil Pressure Sensor Engine Oil Pressure Sensor Harness Engine Harness-to-Engine Oil Pressure Sensor Harness 12-Pin Connector
Section 9015 page 135
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Engine Oil Pressure Sensor Harness (W19) Wiring Diagram
Engine Oil Pressure Sensor Harness (W19) Wiring Diagram LEGEND: B5101 X5003
<- Go to Section TOC
Engine Oil Pressure Sensor Engine Harness-to-Engine Oil Pressure Sensor Harness 12-Pin Connector
Section 9015 page 136
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Engine Crankshaft Sensor Harness (W20) Component Location
Engine Crankshaft Sensor Harness (W20) Component Location LEGEND: B5301 W17 W20 X5301 (B5301)
Engine Crankshaft Sensor Engine Harness Engine Crankshaft Sensor Harness Engine Harnes-to-Engine Crankshaft Sensor Harness 2-Pin Connector
<- Go to Section TOC
Section 9015 page 137
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Engine Crankshaft Sensor Harness (W20) Wiring Diagram
Engine Crankshaft Sensor Harness (W20) Wiring Diagram LEGEND: B5301 X5301 (B5301)
Engine Crankshaft Sensor Engine Harnes-to-Engine Crankshaft Sensor Harness 2-Pin Connector
<- Go to Section TOC
Section 9015 page 138
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Exhaust Aftertreatment Harness (W21) Component Location
Exhaust Aftertreatment Harness (W21) Component Location LEGEND: 1 2 B5109 B5204 B5511 B5512 B5513 W21 X20
<- Go to Section TOC
Pressure Port Pressure Port Diesel Particulate Filter (DPF) Differential Pressure Sensor Exhaust Filter Temperature Module DOC Inlet Temperature Sensor DOC Outlet Temperature Sensor DPF Outlet Temperature Sensor Exhaust Aftertreatment Harness Engine Interface Harness-to-Exhaust Aftertreatment Harness 6-Pin Connector
Section 9015 page 139
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 10: System Diagrams
Exhaust Aftertreatment Harness (W21) Wiring Diagram
Exhaust Aftertreatment Harness (W21) Wiring Diagram LEGEND: B5109 B5204 X20 X1160 X1161
<- Go to Section TOC
Diesel Particulate Filter (DPF) Differential Pressure Sensor Exhaust Filter Temperature Module Engine Interface Harness-to-Exhaust Aftertreatment Harness 6-Pin Connector Splice 5437 PUR Splice 5474 YEL
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Rear View Camera Harnesses (W22 and W23) Component Location
Rear View Camera Harnesses (W22 and W23) Component Location LEGEND: A9 A10 W22 W23 X67
<- Go to Section TOC
Rear View Monitor Rear View Camera Rear View Camera Front Frame Harness Rear View Camera Rear Frame Harness Rear View Camera Articulation 4-Pin Connector
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Rear View Camera Front Frame Harness (W22) Wiring Diagram
Rear View Camera Front Frame Harness (W22) Wiring Diagram LEGEND: A9 X67
<- Go to Section TOC
Rear View Monitor Rear View Frame Camera Articulation 4-Pin Connector
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Rear View Camera Rear Frame Harness (W23) Wiring Diagram
Rear View Camera Rear Frame Harness (W23) Wiring Diagram LEGEND: A10 X67
<- Go to Section TOC
Rear View Camera Rear View Frame Camera Articulation 4-Pin Connector
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Group 10: System Diagrams
Diesel Fired Coolant Heater (DFCH) Harnesses (W24 and W25) Component Location
Diesel Fired Coolant Heater (DFCH) Harnesses (W24 and W25) Component Location LEGEND: A15 Coolant Heater Control Module E13 Coolant Heater Unit F44 Coolant Heater Control Unswitched 15-Amp Fuse (inline) F45 Coolant Heater Control Return (ground) 5-Amp Fuse (inline) F46 Coolant Heater Module Switched 5-Amp Fuse (inline) S1 Battery Disconnect Switch W24 Diesel Fired Coolant Heater (DFCH) Harness W25 Diesel Fired Coolant Heater (DFCH) Control Harnesses X7 Diesel Fired Coolant Heater (DFCH) Control Harness-to-Diesel Fired Coolant Heater (DFCH) Harness 4-Pin Connector X30 Fuse Block Switched Power Terminal X54 Fuse Block X50 Remote Battery Positive (+) Charge Post <- Go to Section TOC
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X51 Y47
Group 10: System Diagrams
Remote Battery Negative (-) Charge Post Coolant Heater Fuel Pump
<- Go to Section TOC
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Diesel Fired Coolant Heater (DFCH) Harness (W24) Wiring Diagram
Diesel Fired Coolant Heater (DFCH) Harness (W24) Wiring Diagram LEGEND: E13 Coolant Heater Unit F44 Coolant Heater Control 15-Amp Fuse (inline) X7 Diesel Fired Coolant Heater (DFCH) Control Harness-to-Diesel Fired Coolant Heater (DFCH) Harness 4-Pin Connector X50 Remote Battery Positive (+) Charge Post X51 Remote Battery Negative (-) Charge Post X1170 Splice P90 RED X1171 Splice G51 BLK Y47 Coolant Heater Fuel Pump
<- Go to Section TOC
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Diesel Fired Coolant Heater (DFCH) Control Harness (W25) Wiring Diagram
Diesel Fired Coolant Heater (DFCH) Control Harness (W25) Wiring Diagram LEGEND: A15 Coolant Heater Control Module F46 Coolant Heater Module Switched 5-Amp Fuse (inline) X7 Diesel Fired Coolant Heater (DFCH) Control Harness-to-Diesel Fired Coolant Heater (DFCH) Harness 4-Pin Connector X30 Fuse Block Switched Power Terminal X1175 Splice G51 BLK
<- Go to Section TOC
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JDLink™ Harnesses (W6002 and W6003) Component Location
JDLink™ Modular Telematics Gateway (MTG) Control Unit LEGEND: 1 2 A6000 A6001
Modular Telematics Gateway (MTG) Control Unit Modular Telematics Gateway (MTG) Control Unit and Satellite (SAT) Module Control Unit JDLink ™ Modular Telematics Gateway (MTG) Control Unit GPS/Cellular Antenna
<- Go to Section TOC
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A6002 A6003 W6002 W6003 X31 X6001 X6002 X6005 X6014 X6015 X6016
Group 10: System Diagrams
Satellite (SAT) Module Control Unit (if equipped) Satellite Antenna (if equipped) JDLink Modular Telematics Gateway (MTG) Harness JDLink Satellite(SAT) Harness Cab Harness-to-JDLink™ Harness 12-Pin Connector Cellular Antenna Connector GPS Antenna Connector Satellite Antenna Connector Moduar Telematics Gateway (MTG) 48-Pin Connector Satellite (SAT) Module Control Unit 48-Pin Connector Satellite Adapter Harness-to-Universal JDLink™ Harness 6-Pin Connector
<- Go to Section TOC
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Group 10: System Diagrams
JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram
JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram LEGEND: X31 X1500 <- Go to Section TOC
Cab Harness-to- JDLink ™ Harness 12-Pin Connector Splice G10 BLK Section 9015 page 150
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X1501 X6014 X6016
<- Go to Section TOC
Group 10: System Diagrams
Splice P84 RED Modular Telematics Gateway (MTG) 48-Pin Connector Satellite Adapter Harness-to-Universal JDLink™ Harness Connector
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Group 15: Sub-System Diagnostics
JDLink™ Satellite (SAT) Harness (W6003) Wiring Diagram—If Equipped
JDLink™ Satellite (SAT) Harness (W6003) Wiring Diagram—If Equipped LEGEND: X6015 X6016
<- Go to Section TOC
JDLink ™ Satellite Module Connector Satellite Adapter Harness-to-Universal JDLink™ Harness Connector
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Group 15 - Sub-System Diagnostics
<- Go to Section TOC
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Group 15: Sub-System Diagnostics
24-Volt Power and Ground Circuits Theory of Operation
24-Volt Power and Ground Circuits Schematic
<- Go to Section TOC
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LEGEND: A2 A8 E9 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30 F50 F51 F52 G1 G3 K1 K2 M1 S1 V1 V3 W30 W31 W32 W33 W34 W35 W36 W37 X15 X24 X29 X30 X50 X51
Group 15: Sub-System Diagnostics
25-Button Sealed Switch Module (SSM) (OC3) Chassis Control Unit (CCU) Interior Light SSM-25 and Interior Light 10-Amp Fuse Spare 10-Amp Fuse Horn 10-Amp Fuse Brake Light Switch 10-Amp Fuse Stairwell and Service Lights 10-Amp Fuse Chassis Control Unit (CCU) VP2 Unswitched Power 10-Amp Fuse Chassis Control Unit (CCU) VP3 Unswitched Power 20-Amp Fuse CAN Monitor Unit (CMU) Unswitched Power 10-Amp Fuse 24V/12V Converter (15A) Unswitched Power 15-Amp Fuse 24V/12V Converter (25A) Unswitched Power 25-Amp Fuse Transmission Control Unit (TCU) Unswitched Power 10-Amp Fuse Service ADVISOR ™ Diagnostic Connector 10-Amp Fuse JDLink ™ Unswitched Power 10-Amp Fuse Engine Control Unit (ECU) Unswitched Power 20-Amp Fuse Fuel Dosing Pump 15-Amp Fuse (not used) Low Pressure Fuel Pump 15-Amp Fuse Headlights, Tail Lights, and Turn Lights 15-Amp Fuse Wiper Motor 10-Amp Fuse Mirror Switch 10-Amp Fuse Air Conditioner Unit (ACU) 10-Amp Fuse Chassis Control Unit (CCU) VELX Switched Power 5-Amp Fuse CMU and SSM-15 Switched Power 5-Amp Fuse 24V/12V Converter Switched Power 10-Amp Fuse Onboard Weighing (OBW) and Tire Pressure Monitor System (TPMS) 10-Amp Fuse Transmission Control Unit (TCU) Switched Power 10-Amp Fuse Auto Greasing Indicator and Rear View Monitor 5-Amp Fuse JDLink ™ Switched Power 5-Amp Fuse Engine Control Unit (ECU) Switched Power 5-Amp Fuse Spare 5-Amp Fuse Seat Compressor and Brake Accumulator Low Pressure Sensor 10-Amp Fuse Main 60-Amp Circuit Breaker Fuel Filter Heater 20-Amp Circuit Breaker (if equipped) JDLink Return (ground) 5-Amp Fuse (inline) Battery (2 used) Alternator Ignition Relay Starter Relay Starter Motor Battery Disconnect Switch Ignition Relay Diode Starter Motor Diode Engine Interface Harness Ground Cab Ground Starter Motor Ground Front Frame Harness Ground Hydraulic Harness Ground Air Conditioner Ground Machine Frame-to-Cab Frame Ground Cable Engine Block-to-Machine Frame Ground Strap Cab Harness-to-Front Frame Harness 9-Pin Connector Chassis Control Unit (CCU) (VP1) 1-Pin Connector Fuse Block Unswitched Power Terminal Fuse Block Switched Power Terminal Remote Positive Battery Charge Post Remote Negative Battery Charge Post
Battery (G1)— The machine’s electrical system is powered by two 12-volt batteries connected in series to provide 24 volts of power. The 24-volt electrical system consists of an unswitched power circuit and a switched power circuit. Unswitched Power— The unswitched power circuit provides power directly from the battery to a device whether the ignition is ON or OFF. Unswitched power from the battery is supplied to the following components via the remote positive battery charge post (X50): Starter Motor (M1) <- Go to Section TOC
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Alternator (G3) (B+ terminal) Starter Relay (K2) (contacts) Main 60-Amp Circuit Breaker (F50) →NOTE: The remote battery charge posts (X50) (positive) and (X51) (negative) provide a convenient location for jump starting the machine using a 24-volt boost pack or charging the batteries using a 24-volt battery charger. From the main 60-amp circuit breaker (F50), unswitched power is supplied to the contacts of ignition relay (K1) and to terminal (X29) on the fuse block. From terminal (X29), unswitched power is supplied to the following fuses: F1—SSM-25 and Interior Light 10-Amp Fuse F2—Spare 10-Amp Fuse F3—Horn 10-Amp Fuse F4—Brake Light Switch 10-Amp Fuse F5—Stairwell and Service Lights 10-Amp Fuse F6—CCU VP2 Unswitched Power 10-Amp Fuse F7—CCU VP3 Unswitched Power 20-Amp Fuse F8—CMU Unswitched Power 10-Amp Fuse F9—24V/12V Converter (15A) Unswitched Power 15-Amp Fuse F10—24V/12V Converter (25A) Unswitched Power 25-Amp Fuse F11—TCU Unswitched Power 10-Amp Fuse F12— Service ADVISOR ™ Diagnostic Connector Unswitched Power 10-Amp Fuse F13— JDLink ™ Unswitched Power 10-Amp Fuse F14—ECU Unswitched Power 20-Amp Fuse F15—Fuel Dosing Pump 15-Amp Fuse F16—Low Pressure Fuel Pump 15-Amp Fuse Fuse (F1) provides unswitched power to the interior light (E9) and to pin 1 on the 25-button sealed switch module (SSM) (OC3) (A2). Switched Power— The switched power circuit provides power to a device only when the ignition is ON. When the engine start button on the 25-button SSM is pushed and released, current available at pin 1 of the SSM flows out of the SSM at pin 3 to the coil (pin C1) on ignition relay (K1), energizing the relay. With the ignition relay energized, switched power is now available to the fuel filter heater 20-amp circuit breaker (F51) (if equipped) and to terminal (X30) on the fuse block. From terminal (X30), switched power is supplied to the VP1 connector (X24) on the chassis control unit (CCU) (A8) and to the following fuses: F17—Headlights, Tail Lights, and Turn Lights 15-Amp Fuse F18—Wiper Motor 10-Amp Fuse F19—Mirror Switch 10-Amp Fuse F20—Air Conditioner Unit (ACU) 10-Amp Fuse F21—CCU VELX Switched Power 5-Amp Fuse F22—CMU and SSM-15 Switched Power 5-Amp Fuse F23—24V/12V Converter Switched Power 10-Amp Fuse F24—OBW and TPMS 10-Amp Fuse F25—TCU Switched Power 10-Amp Fuse F26—Auto Greasing Indicator and Rear View Monitor 5-Amp Fuse F27—JDLink™ Switched Power 5-Amp Fuse F28—ECU Switched Power 5-Amp Fuse F29—Spare 5-Amp Fuse F30—Seat Compressor and Brake Accumulator Low Pressure Sensor 10-Amp Fuse Battery Disconnect Switch (S1)— All 24-volt electrical circuits return to the battery negative (-) terminal through battery disconnect switch (S1) with the exception of the fused return (ground) for JDLink. The fused return for JDLink connects directly to the battery side of the disconnect switch through the inline 5-amp fuse (F52). For more information on JDLink, see JDLink™ Circuit Theory of Operation . (Group 9015-15.) <- Go to Section TOC
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The battery disconnect switch must be in the ON position for machine operation. When the battery disconnect switch is in the OFF position, the return (ground) side of the electrical system is isolated from the battery’s negative (-) terminal, preventing all electrical systems from operating except certain functions of JDLink. Turning the switch to OFF provides the following: Security and anti-theft. Extended life of battery charge during extensive machine downtime. Disabling of the machine’s electrical system for servicing and repair. System Grounds— The electrical system contains the following ground points and cables: W30—Engine Interface Harness Ground. (Ground point for engine interface harness components.) W31—Cab Ground. (Ground point for cab harness components.) W32—Starter Motor Ground. [Provides main ground tie point between battery disconnect switch (S1) and alternator (G3).] W33—Front Frame Harness Ground. (Ground point for front frame harness components.) W34—Hydraulic Harness Ground. (Ground point for hydraulic harness components.) W35—Air Conditioner Ground. (Ground point for air conditioner unit components.) W36—Machine Frame-to-Cab Frame Ground Cable. (Ensures cab frame is electrically grounded to machine frame.) W37—Engine Block-to-Machine Frame Ground Strap. [Connects starter motor ground (W32) to engine interface harness ground (W30).] X50—Remote negative battery charge post. [Used in conjunction with remote positive battery charge post (X51) for jump starting the machine using a 24-volt boost pack or charging the batteries using a 24-volt battery charger.] For location of ground points and cables, see Power and Ground Component Location . (Group 9015-10.)
<- Go to Section TOC
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Group 15: Sub-System Diagnostics
12-Volt Power Circuits Theory of Operation
12-Volt Power Circuits Schematic
<- Go to Section TOC
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LEGEND: A8 A12 B45 B46 F9 F10 F23 F31 F32 F33 F34 F35 F36 F37 R8 U1 W29 W31 X23 X29 X30 X34 X38 X41 X42 X55 X56
Group 15: Sub-System Diagnostics
Chassis Control Unit (CCU) AM/FM Radio Left Speaker Right Speaker 24V/12V Converter (15A) Unswitched Power 15-Amp Fuse 24V/12V Converter (25A) Unswitched Power 25-Amp Fuse 24V/12V Converter Switched Power 10-Amp Fuse Lighter 10-Amp Fuse 2-Way Radio 10-Amp Fuse 24V/12V Converter Monitoring 10-Amp Fuse 12-Volt Power Outlet 10-Amp Fuse Radio Switched Power 10-Amp Fuse Ground Speed Radar 5-Amp Fuse Radio Memory 5-Amp Fuse Lighter 24V to 12V DC Converter AM/FM Radio Antenna Cab Ground Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Unswitched Power Terminal Fuse Block Switched Power Terminal 12-Volt Power Outlet Cab Harness-to-AM/FM Radio Harness 3-Pin Connector Left 2-Way Radio 2-Pin Connector Right 2-Way Radio 2-Pin Connector 24V/12V Converter 6-Pin Connector 24V/12V Converter 4-Pin Connector
24V to 12V DC Converter (U1)— The DC converter is used to change system voltage from 24 volts to 12 volts. The standard unit is rated at 15 amps, which uses only connector (X55). The machine may be equipped with an optional unit rated at 25 amps, which uses both connectors (X55 and X56). The DC converter receives 24-volt unswitched power from fuse (F9) at pin 1 on connector (X55). It also receives 24-volt unswitched power from fuse (F10) at pin 1 on connector (X56). The DC converter ground is provided by cab ground (W31) at pin 3 on connector (X55) and at pin 2 on connector (X56). When ignition power is ON, 24-volt power is supplied to the DC converter at pin 2 on connector (X55) via fuse (F23), activating the 12-volt switched outputs. →NOTE: For 24-volt switched power and unswitched power circuit information between the battery and the fuses, see 24-Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) 12-Volt Switched Power— With ignition power ON, 12-volt power at pin 5 on connector (X55) and pin 3 on connector (X56) (if equipped with 25-amp unit) becomes available to the following components: Lighter (R8) [via fuse (F31)] 2-Way Radio Connectors (X41 and X42) [via fuse (F32)] 12-Volt Power Outlet (X34) [via fuse (F34)] AM/FM Radio (A12) (pin A7) [via fuse (F35)] Fuse (F36) Chassis Control Unit (CCU) (A8) [pin 8, connector (X23)] [via fuse (F33)] Fuse (F36) provides switched 12-volt power to the ground speed radar unit. For information on the ground speed radar circuit, see Differential Lock Circuits Theory of Operation . (Group 9015-15.) The CCU monitors the voltage at pin 8 on CCU connector (X23) to determine the status of the 24V to 12V DC converter. →NOTE: Status of the DC converter can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / POWER submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) When 12-volt power is available at pin A7 of the AM/FM radio, the radio will power up when the radio ON/OFF button is pushed. <- Go to Section TOC
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12-Volt Unswitched Power— The AM/FM radio (A12) uses the 12-volt unswitched power from pin 4 on connector (X55), via fuse (F37), for storing the clock and channel settings in memory.
<- Go to Section TOC
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Group 15: Sub-System Diagnostics
Controller Area Network (CAN) Circuit Theory of Operation
Controller Area Network (CAN) Circuit Schematic
<- Go to Section TOC
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LEGEND: A1 A2 A3 A5 A7 A8 A18 A19 A6000 B5500 F12 L3 R1 R2 R3 R4 R7 W3 W9 W11 W12 W18 W30 W31 W34 W6002 X2 X3 X8 X9 X11 X13 X16 X21 X29 X31 X40 X70 X5015 X6014 Y5500 Y5501 Y5502
Group 15: Sub-System Diagnostics
15-Button Sealed Switch Module (SSM) (OC4) 25-Button Sealed Switch Module (SSM) (OC3) Engine Control Unit (ECU) Transmission Control Unit (TCU) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Onboard Weighing (OBW) Controller Tire Pressure Monitoring (TPM) System Controller Modular Telematics Gateway (MTG) Intake Air Sensor Service ADVISOR ™ Diagnostic Connector 10-Amp Fuse Onboard Weighing (OBW) CAN Filter Engine Harness CAN 1 Termination Resistor Engine CAN Termination Resistor Cab Harness CAN 2 Termination Resistor OBW/TPMS CAN 2 Termination Resistor Hydraulic Harness CAN 1 Termination Resistor Cab Harness Hydraulic Harness Articulation Harness Rear Frame Harness Engine Interface Harness Engine Interface Harness Ground Cab Ground Hydraulic Harness Ground JDLink MTG Harness Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Engine Control Unit (ECU) Connector (A5501) Engine Control Unit (ECU) Connector (A5503) Cab Harness-to-Engine Harness 14-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Fuse Block Unswitched Power Terminal Cab Harness-to-JDLink™ Harness 12-Pin Connector Service ADVISOR Diagnostic Connector Transmission Control Unit (TCU) 21-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector Variable Geometry Turbocharger (VGT) Actuator Low Pressure Fuel Pump Fuel Dosing Pump
Controller Area Network (CAN) Overview— The CAN data line 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, which helps the devices communicate with minimal errors. To help prevent signal errors, the CAN data line uses 120-ohm termination resistors, usually located at opposite ends of the CAN data line. 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 data line is idle before it transmits a signal. Whichever device gets on the data line first is able to transmit its signal. When collision occurs, that is, 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.) This machine contains three CAN circuits: CAN 1, CAN 2, and the engine CAN. <- Go to Section TOC
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CAN 1— provides the communication link for the following devices: Engine Control Unit (ECU) (A3) Transmission Control Unit (TCU) (A5) Chassis Control Unit (CCU) (A8) Modular Telematics Gateway (MTG) (A6000) CAN Monitor Unit (CMU) (A7) Sealed Switch Modules (SSM) (A1 and A2) Operations and functions of these individual devices on CAN 1 are covered separately. For the ECU, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) For the TCU, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) For the CCU, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For the CMU and SSM, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) For the MTG, see System Overview in JDLink™ (MTG) Diagnosis and Test Manual. (TM114519.) CAN 1 also includes the following components: R1—Engine Harness CAN 1 Termination Resistor R7—Hydraulic Harness CAN 1 Termination Resistor X40— Service ADVISOR ™ Diagnostic Connector The diagnostic connector provides an interface for connecting diagnostic equipment such as a laptop. See Service ADVISOR™ Connection Procedure . (Group 9015-20.) CAN 2— provides the communication link for the following devices: Chassis Control Unit (CCU) (A8) Onboard Weighing (OBW) Controller (A18) Tire Pressure Monitor (TPM) System Controller (A19) Operations and functions of these individual devices on CAN 2 are covered separately. For the CCU, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For the OBW system, see Onboard Weighing (OBW) Controller Circuit Theory of Operation . (Group 9015-15.) For the TPM system, see Tire Pressure Monitoring (TPM) System Theory of Operation . (Group 9015-15.) CAN 2 also includes the following components: R3—Cab Harness CAN 2 Termination Resistor R4—OBW/TPMS CAN 2 Termination Resistor X40— Service ADVISOR ™ Diagnostic Connector Engine CAN— provides the communication link for the following devices: A3—Engine Control Unit (ECU) B5500—Intake Air Sensor Y5500—VGT Actuator Y5501—Low Pressure Fuel Pump Y5502—Fuel Dosing Pump The engine CAN also includes the engine CAN termination resistor (R2) embedded in the engine harness. Operations and functions of the individual devices on the engine CAN are covered separately. See Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.)
<- Go to Section TOC
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Start and Charge Circuits Theory of Operation
Start and Charge Circuits Schematic
<- Go to Section TOC
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LEGEND: A2 A3 A5 A7 A8 B5301 F1 F14 F16 F28 F50 G1 G3 K1 K2 M1 R10 S1 V1 V2 V3 W30 W31 W32 W33 W34 W36 W37 X8 X9 X11 X13 X15 X16 X21 X22 X23 X29 X30 X50 X51 X70 X5015 Y2 Y11 Y5501
Group 15: Sub-System Diagnostics
25-Button Sealed Switch Module (SSM) (OC3) Engine Control Unit (ECU) Transmission Control Unit (TCU) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Crankshaft Position Sensor SSM-25 and Interior Light 10-Amp Fuse ECU Unswitched Power 20-Amp Fuse Low Pressure Fuel Pump 15-Amp Fuse ECU Switched Power 5-Amp Fuse Main 60-Amp Circuit Breaker Battery (2 used) Alternator Ignition Relay Starter Relay Starter Motor Fuel Filter Heater Battery Disconnect Switch Ignition Relay Diode Starter Relay Diode Starter Motor Diode Engine Interface Harness Ground Cab Ground Starter Motor Ground Front Frame Harness Ground Hydraulic Harness Ground Machine Frame-to-Cab Frame Ground Cable Engine Block-to-Machine Frame Ground Strap Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Engine Control Unit (ECU) Connector (A5501) Engine Control Unit (ECU) Connector (A5503) Cab Harness-to-Front Frame Harness 9-Pin Connector Cab Harness-to-Engine Harness 14-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Unswitched Power Terminal Fuse Block Switched Power Terminal Remote Battery Positive Charge Post Remote Battery Negative Charge Post Transmission Control Unit (TCU) 21-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Axle Cooling Cut-Off Solenoid Right Side Fan Cut-Off Solenoid Low Pressure Fuel Pump
Unswitched power is supplied to the following components: M1—Starter Motor G3—Alternator (B+ terminal) K1—Ignition Relay (contacts) [via circuit breaker (F50)] K2—Starter Relay (contacts) A2—25-Button Sealed Switch Module (SSM) (OC3) [pin 1 via fuse (F1)] A3—Engine Control Unit (ECU) [pins 13, 14, 23, and 24 on connector (X13) via fuse (F14)] Ignition ON— When the engine start button is pushed once and released, current flows from pin 3 of SSM (A2) to the coil of ignition relay (K1), energizing the relay. With the ignition relay energized, current flows through fuse (F28) to pin 7 on ECU connector (X13), powering up the ECU. At same time with the ignition relay energized, current flows through circuit breaker (F51) to fuel filter heater (R10).
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Group 15: Sub-System Diagnostics
→NOTE: For information and power-up of the other electronic controllers and the CAN monitor unit (CMU), see the theory of operation of specific component in Group 9015-15. →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) When powered up, the SSM sends a message across the controller area network (CAN) to the CCU that the engine start switch has been pushed. The CCU acknowledges by sending a message back to the SSM, causing the ignition power status (left) LED on the engine start button to come on. For CAN circuit operation, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) With the ECU powered up, the ECU activates low pressure fuel pump (Y5501). The low pressure fuel pump primes the fuel system prior to cranking the engine. For more information on the low pressure fuel pump, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) Anti-Theft Security System— Upon ignition power-up, the CCU checks if security is enabled. If enabled, the CCU starts a 5minute timer and, at the same time, sends a security message across the CAN to the CAN monitor unit (CMU) (A7). The message to the CMU causes a security screen to appear on the monitor display, requiring a valid PIN be entered before the engine can be started. For information on entering the PIN, see CAN Monitor Unit (CMU)—Main Menu—Security . (Operator’s Manual.) If a valid PIN is not entered within 5 minutes after ignition power-up, the CCU will turn off ignition power. When a PIN is required to start the engine and the delayed operator logout option is not set to OFF, the engine can be restarted without re-entering the PIN if the engine is started within either 5 minutes or 60 minutes (depending on setting) of stopping the engine. If OFF is selected in the delayed operator logout menu, the PIN will need to be entered at each start-up. The delayed logout setting can be changed by accessing the SECURITY / DELAYED OPERATOR LOGOUT submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Security . (Operator’s Manual.) If ignition power is on, but the engine is not started for 60 minutes after ignition is turned on, the CCU will turn off ignition power. If security is not enabled or after the security PIN has been successfully entered, pushing the engine start button again will crank and start the engine. Engine Start— When the engine start button is pushed a second time and held down for more than 1.5 seconds, the SSM broadcasts a message across the CAN to request the CCU begin the start process. Upon receiving the start message, the CCU then checks for the following: Current Gear = Neutral Selected Gear = Neutral Park Brake = Engaged Transmission Output Shaft Speed less than 100 rpm Starter Persistence Timer = 0 Engine Not Running When satisfied with the previous checks, the CCU then performs the following: [1] - The CCU deactivates the air conditioner, work lights, service lights, and rotating beacon to reduce the electrical load during cranking. [2] - The CCU sends current from pin 21 on CCU connector (X23) to the right side fan cut-off solenoid (Y11), energizing the solenoid. The energized fan cut-off solenoid prevents hydraulic flow to the right fan motor, which reduces the parasitic load on the engine during cranking. For more information on the hydraulic fan control, see Hydraulic Fan Control Circuits Theory of Operation . (Group 9015-15.) [3] - The CCU sends current from pin 44 on CCU connector (X22) to the axle cooling cut-off solenoid (Y2), energizing the solenoid. The energized axle cooling cut-off solenoid prevents hydraulic flow to the axle cooling hydraulic motor, which reduces the parasitic load on the engine during cranking. For more information on the axle cooling electrical circuits, see Axle Cooling and Lubrication Circuits Theory of Operation . (Group 9015-15.) <- Go to Section TOC
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For hydraulic operation, see Hydraulic System Manifold Operation . (Group 9025-05.) [4] →NOTE: To prevent overheating the starter motor, the ECU is equipped with a persistence timer that affects the amount of time the engine is allowed to crank and the amount of time allowed for the starter to cool down. Anytime the start input is active, the persistence timer will count up. During this time, the ECU enables the start output driver, providing current to the starter relay until the persistence timer reaches the maximum cranking limit. When the start input is not active, the persistence timer will count down. The maximum crank time can be anything from 30 to 120 seconds, depending on temperature and engine speed. When the maximum cranking limit is reached, the starter control will enable cool-down mode, which disables the start output driver until the persistence timer reaches 0. The maximum cool-down time is 120 seconds. The ratio of maximum cranking time to cool-down time is 1 to 2. Example: A 30-second maximum crank time will produce a 60-second cool-down time. Or a 60-second maximum crank time will produce a 120-second cool-down time. Any maximum crank time longer than 60 seconds will have a cool-down time of 120 seconds. The CCU broadcasts the start request signal across the CAN to the ECU. The ECU then checks the status of the persistence timer and the signal from crankshaft position sensor (B5301) representing engine speed. If the engine speed is less than 38 rpm and the persistence timer equals 0, the ECU will enable the high-side driver at pin 30 and the low-side driver at pin 26 of ECU connector (X13). This allows current from the ECU to flow through the coil of starter relay (K2), energizing the relay. At the same time, the CCU sends a message back to the SSM, causing the engine crank status (right) LED on the engine start button to come on. The right LED will be on only when the button is held down during the cranking process. →NOTE: The starter input signal can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / DIGITAL INPUTS submenu of the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) With the starter relay energized, current direct from the battery flows to the starter motor solenoid, activating the starter motor (M1). At the same time, the ECU activates the persistence timer, which starts counting up. If the engine start switch is held down for the maximum allowable limit of continuous engine cranking, the ECU interrupts current flow to the coil of the starter relay, which automatically stops cranking of the engine. When the ECU detects that the crankshaft is turning at a predetermined speed, it will start the fuel injection process, and thus start the engine. During start-up, the accelerator pedal has no effect on fuel delivery. The ECU determines proper delivery time and quantity to ensure correct start-up and lower emissions. For more information on the ECU and the fuel system, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) Engine and Transmission Warm-Up— When the CCU detects the transmission oil temperature is less than -12°C (10°F) at engine start-up, the CCU will transmit a CAN message to the ECU, requesting engine slow idle speed to be 1000 rpm for 30 seconds to allow for initial engine warm-up. After the 30 seconds have elapsed, the CCU will request the ECU to ramp up the engine speed to approximately 1180 rpm to warm up the transmission oil and to continue warming the engine. The engine slow idle speed will hold at 1180 rpm until the transmission oil temperature reaches 30°C (86°F), at which point, the CCU ramps down engine slow idle speed to 900 rpm. →NOTE: When the transmission oil temperature is less than -12°C (10°F), the CCU will prevent the transmission from shifting into gear. When the transmission oil temperature is between -12°C and 30°C (10°F and 86°F) at engine start-up, the CCU requests engine slow idle speed to immediately go to 1100 rpm. The engine slow idle speed will hold at 1100 rpm until the transmission oil temperature reaches 30°C (86°F), at which point, the CCU ramps down engine slow idle speed to 900 rpm. Charge Circuit— Alternator (G3) provides power to all machine circuits and charges the batteries when the engine is running. <- Go to Section TOC
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Terminal B+ of the alternator is connected to battery positive (+) at all times. When ignition power is ON and engine is running, current flows from pin 29 of ECU connector (X13) to the D+ terminal on the alternator. The current then flows through the alternator field windings, causing excitation of the windings. If the ECU senses that the output at pin 29 on ECU connector (X13) is below a predetermined threshold for more than 10 seconds when engine is running, the ECU will generate a DTC and transmit a CAN message to the CCU to inform the CCU of the alternator state. The CCU then sends a message across the CAN data line to the CMU, causing the battery voltage indicator to come on. The battery charge indicator will also come on if ignition is ON and engine is off. →NOTE: The charging state of the alternator can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / INPUT SENSORS submenu of the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) For more information, see Alternator Test . (Group 9015-20.)
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Cold Start Aid Circuits Theory of Operation
Cold Start Aid Circuits Schematic
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LEGEND: A2 A3 A15 B5208 B5209 E13 F1 F44 F46 F50 G1 K1 R10 S1 V1 W30 W31 W33 X7 X11 X12 X13 X15 X16 X29 X30 X50 X51 X5016 Y15 Y47
Group 15: Sub-System Diagnostics
25-Button Sealed Switch Module (SSM) (OC3) Engine Control Unit (ECU) Coolant Heater Control Module Engine Coolant Temperature Sensor Fuel Temperature Sensor Coolant Heater Unit SSM-25 and Interior Light 10-Amp Fuse Coolant Heater Control 15-Amp Fuse (inline) Coolant Heater Module 5-Amp Fuse (inline) Main 60-Amp Circuit Breaker Battery (2 used) Ignition Relay Fuel Filter Heater Battery Disconnect Switch Ignition Relay Diode Engine Interface Harness Ground Cab Ground Front Frame Harness Ground Coolant Heater Control Module Harness-to-Coolant Heat Unit Harness 4-Pin Connector Engine Control Unit (ECU) Connector (A5501) Engine Control Unit (ECU) Connector (A5502) Engine Control Unit (ECU) Connector (A5503) Cab Harness-to-Front Frame Harness 9-Pin Connector Cab Harness-to-Engine Harness 14-Pin Connector Fuse Block Unswitched Power Terminal Fuse Block Switched Power Terminal Remote Battery Positive Charge Post Remote Battery Negative Charge Post Engine Interface Harness-to-Engine Harness 40-Pin Connector Ether Start Aid Solenoid Coolant Heater Fuel Pump
Auto-Ether Injection Circuit— The auto-ether injection feature provides two stages of injection: cranking and post start. Cranking: When the engine start switch is pushed once (ignition ON), the ECU receives a fuel temperature signal from the fuel temperature sensor (B5209) at pins 40 and 28 of ECU connector (X12). It also receives a coolant temperature signal from the engine coolant temperature sensor (B5208) at pins 48 and 28 of ECU connector (X12). If the ECU determines that the fuel temperature is -5°C (23°F) or lower when the engine is cranking and engine speed is between 80 and 899 rpm, the ECU sends current from pin 46 on ECU connector (X11) to the ether start aid solenoid (Y15), energizing the solenoid for 30 seconds or until engine speed reaches 900 rpm, which ever comes first. If the fuel temperature is invalid, the ECU will use engine coolant temperature to determine if ether injection is necessary. Ether injection will be disabled if coolant temperature is greater than 40°C (104°F) or if both fuel and coolant temperatures are invalid. For more information on the ECU, fuel temperature sensor, and coolant temperature sensor operation, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) Auto-Ether Injection During Cranking AUTO-ETHER INJECTION DURING CRANKING Fuel Temperature
Ether Injection Time
0°C (32°F) or higher
0 seconds
-5°C (23°F) or lower
30 seconds
Post Start: If the fuel temperature and coolant temperature are below a specified set point when engine speed reaches 900 rpm, the ECU energizes the ether start aid solenoid again for a duration indicated in the following table. This is to clean up exhaust smoke and provide stability at start-up.
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Auto-Ether Injection at Post Start AUTO-ETHER INJECTION AT POST START Fuel and Coolant Temperatures
Ether Injection Time
-15°C (5.0°F) or higher
0 seconds
-20°C (-4.0°F) or lower
7.5 seconds
→NOTE: For diesel fired coolant heater repair and diagnostics, See Coolant Heater Service Manual. Coolant heater service manual has been added to John Deere bookstore as CTM10090X19. Diesel Fired Coolant Heater (DFCH)— The DFCH consists of the following major components: Coolant Heater Control Module (A15) Coolant Heater Unit (E13) Coolant Heater Fuel Pump (Y47) Unswitched power is supplied to pin 11 on the coolant heater control module and to pin A3 on the coolant heater unit via fuse (F44). Return ground is provided at pins 4 and 12 on the coolant heater control module and at pin A2 on the coolant heater unit. When the engine start button is pushed once and released, current flows from pin 3 of the 25-button sealed switch module (SSM) (OC3) (A2) to the coil of ignition relay (K1), energizing the relay. With the ignition relay energized, current flows through fuse (F46) to pin 10 on the coolant heater control module, providing power for the control module’s LCD display and internal logic. The coolant heater control module contains a timer that operates using unswitched power. When triggered, the timer takes unswitched current available at pin 11 of the control module and sends it out pin 2 to the coolant heater unit at pin C4. When the coolant heater unit receives current at pin C4, the start sequence is initiated. After approximately 25 seconds, the heater unit sends current out pin A1 to the coolant heater fuel pump, activating the fuel pump. For operation of the coolant heater, see Cold Start Aids Theory of Operation—If Equipped . (Group 9010-05.) If the system malfunctions, the coolant heater unit sends a diagnostic code out pin B4 to pin 8 on the coolant heater control module, where the diagnostic code can be read. Fuel Filter Heater Fuel filter heater (R10) is a resistor element located inside the auxiliary fuel filter and water separator. Fuel filter heater receives power through fuel filter heater 20 A circuit breaker (F51) when ignition relay (K1) is energized. An internal thermostat controls fuel filter heater operation.
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Group 15: Sub-System Diagnostics
Engine Control Unit (ECU) Circuits Theory of Operation
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Engine Control Unit (ECU) Circuit Schematic (1 of 3)
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LEGEND: A2 A3 A5 A7 A8 A6000 B18 B19 B20 F14 F28 G3 K2 W30 X9 X13 X16 X21 X29 X30 X31 X70
Group 15: Sub-System Diagnostics
25-Button Sealed Switch Module (SSM) (OC3) Engine Control Unit (ECU) Transmission Control Unit (TCU) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Modular Telematics Gateway (MTG) Accelerator Pedal Sensor Engine Coolant Loss Service Switch Engine Coolant Loss Alarm Switch ECU Unswitched Power 20-Amp Fuse ECU Switched Power 5-Amp Fuse Alternator Starter Relay Engine Interface Harness Ground Cab Harness-to-Hydraulic Harness 31-Pin Connector Engine Control Unit (ECU) 54-Pin Connector Cab Harness-to-Engine Harness 14-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Fuse Block Unswitched Power Terminal (marked as Stud 1) Fuse Block Switched Power Terminal (marked as Stud 2) Cab Harness-to- JDLink ™ Harness 12-Pin Connector Transmission Control Unit (TCU) 21-Pin Connector
→NOTE: Whenever the engine control unit (ECU) is replaced, the new controller must be programmed according to the machine serial number to ensure correct software is installed. →NOTE: The software version, software part number, and hardware part number for the ECU can be accessed in the DIAGNOSTICS / PARTS INFO / STANDARD PARTS / ECU submenu of the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics—Part Info . (Operator’s Manual.) Engine Control Unit (ECU) (A3)— 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 broadcast on the controller area network (CAN) to the transmission control unit (TCU) (A5), chassis control unit (CCU) (A8), and MTG controller (A6000). The CCU forwards much of the information across the CAN data line to the CAN monitor unit (CMU) (A7), where it is displayed. For CAN operation, see Controller Area Network (CAN) 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 generates a diagnostic trouble code (DTC). For a list of engine diagnostic trouble codes see the following: Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.) Diagnostic Trouble Code (DTC) Group Locator . (CTM104919.) When an engine DTC occurs, the information is captured and recorded in the ECU. The captured information is called a snapshot. For more information, see Snapshot Instructions . (CTM104919.) ECU Power-Up (power and ground)— Unswitched power from fuse (F14) is available at pins 13, 14, 23, and 24 on ECU connector (X13). The engine interface harness ground (W30) provides ground to the ECU at pins 27, 43, and 44 on ECU connector (X13). When ignition is ON, current flows through fuse (F28) to pin 7 on ECU connector (X13), causing the ECU to power up. The voltage at pin 7 can be monitored by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / OTHER INPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) For switched power and unswitched power circuit information between the battery and the fuses, see 24-Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) →NOTE: For information and power-up of the other electronic controllers and the CAN monitor unit (CMU), see the theory of operation of specific component in Group 9015-15. Accelerator Pedal Sensor (B18)— The accelerator pedal sensor is a Hall-effect sensor that is attached to the accelerator <- Go to Section TOC
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pedal. The ECU supplies a 5-volt reference voltage to the accelerator pedal sensor at pin 49 on ECU connector (X13). The ECU provides a return ground for the sensor at pin 33 on ECU connector (X13). The accelerator pedal sensor sends an analog voltage signal representing throttle request to pin 10 on ECU connector (X13). The throttle self-calibrates by automatically adjusting the throttle dead-band with every full range sweep of the accelerator pedal from slow idle to fast idle positions. For more information on self-calibration, see Throttle Self-Calibration . (CTM104919.) The ECU will self-calibrate after each power cycle to learn the valid limits of the throttle. If the throttle signal is out-of-range (OOR), the throttle will be set to zero. For more information, see Throttle Adjustments . (CTM104919.) →NOTE: The accelerator pedal position can be observed as a percentage by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) Engine Coolant Loss Service Switch (B19)— The engine coolant loss service switch is a reed switch that is attached to the bottom of the coolant surge tank and identified by two dashes near the switch port. A float associated with the reed switch rises and lowers with the coolant level. At the bottom of the float is a ring magnet. As long as sufficient coolant level is present, the float (and magnet) is held far enough above the switch so the magnetic field does not affect the switch. The normally closed switch stays closed, providing a ground to pin 38 on ECU connector (X13). If the coolant level drops below a predetermined level, the float will lower to the bottom of the tank, putting the magnet near the engine coolant loss service switch. The magnetic field causes the switch to open. If the switch is open for more than 0.2 second when the ignition is ON (engine off or during cranking) and engine coolant temperature is between -20°C (-4°F) and 60°C (140°F), the ECU will generate a moderately low coolant level DTC. The ECU ignores the switch signal when the engine is running. →NOTE: The engine coolant level can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) Engine Coolant Loss Alarm Switch (B20)— The engine coolant loss alarm switch is a reed switch that is attached to the bottom of the coolant surge tank and identified by one dash near the switch port. A float associated with the reed switch rises and lowers with the coolant level. At the bottom of the float is a ring magnet. As long as sufficient coolant level is present, the float (and magnet) is held far enough above the switch so the magnetic field does not affect the switch. The normally closed switch stays closed, providing a ground to pin 22 on ECU connector (X13). If the coolant level drops below a predetermined level, the float will lower to the bottom of the tank, putting the magnet near the engine coolant loss alarm switch. The magnetic field will cause the switch to open. If the switch is open for more than 15 seconds when engine coolant temperature is more than 60°C (140°F), the ECU generates a moderately severe low coolant level DTC. If the switch opens when engine coolant temperature is more than 95°C (140°F), the ECU generates a most severe low coolant level DTC and derates the engine. For information on engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104919.) If the engine coolant loss alarm switch indicates coolant loss, but the engine coolant loss service switch does not for 15 seconds or more, the ECU will generate a coolant level invalid DTC. →NOTE: The float associated with the engine coolant loss service switch is longer than the float associated with the engine coolant loss alarm switch. As coolant level lowers, the magnet for the engine coolant loss service switch will reach the bottom of the surge tank before the magnet for the engine coolant loss alarm switch. Alternator (G3)— When ignition is ON and engine is running, the ECU provides excitation current to the alternator at pin 29 on ECU connector (X13). For more information on the alternator and charge circuit, see Start and Charge Circuits Theory of Operation . (Group 9015-15.) Starter Relay (K2)— When the ECU receives a start request from the CCU, the ECU enables the high side output driver at pin <- Go to Section TOC
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30 and a low side output driver at pin 26 on ECU connector (X13). With the drivers at pins 30 and 26 enabled, current is sent to the coil of the starter relay, energizing the relay. For more information on the start circuit, see Start and Charge Circuits Theory of Operation . (Group 9015-15.)
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Engine Control Unit (ECU) Circuit Schematic (2 of 3)
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LEGEND: A3 B5101 B5102 B5103 B5104 B5107 B5110 B5300 B5301 B5302 B5500 B5600 F15 F16 R2 W30 X11 X12 X16 X29 X5003 X5015 X5016 Y15 Y5400 Y5401 Y5500 Y5501 Y5502
Group 15: Sub-System Diagnostics
Engine Control Unit (ECU) Engine Oil Pressure Sensor Exhaust Manifold Pressure Sensor Exhaust Gas Recirculation (EGR) Flow Sensor Intake Manifold Pressure Sensor High-Pressure Fuel Pressure Sensor Low-Pressure Fuel Pressure Sensor Variable Geometry Turbocharger (VGT) Speed Sensor Crankshaft Position Sensor Camshaft Position Sensor Intake Air Sensor Water-In-Fuel (WIF) Sensor Fuel Dosing Pump 15-Amp Fuse Low Pressure Fuel Pump 15-Amp Fuse Engine CAN Termination Resistor Engine Interface Harness Ground Engine Control Unit (ECU) Connector (A5501) Engine Control Unit (ECU) Connector (A5502) Cab Harness-to-Engine Harness 14-Pin Connector Fuse Block Unswitched Power Terminal (marked as Stud 1) Engine Harness-to-Engine Oil Pressure Sensor Harness 12-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Ether Start Aid Solenoid Exhaust Gas Recirculation (EGR) Valve Actuator Air Throttle Valve Actuator Variable Geometry Turbocharger (VGT) Actuator Low-Pressure Fuel Pump Fuel Dosing Pump
Engine Oil Pressure Sensor (B5101)— The ECU supplies a 5-volt reference voltage to the sensor at pin 22 on ECU connector (X12). The ECU provides a return ground for the sensor at pin 27 on ECU connector (X12). The engine oil pressure sensor sends an analog signal representing oil pressure to pin 7 on ECU connector (X12). →NOTE: The signal from the engine oil pressure sensor can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) For operation of the engine oil pressure sensor, see B5101 - Engine Oil Pressure Sensor . (CTM104919.) Exhaust Manifold Pressure Sensor (B5102)— The ECU supplies a 5-volt reference voltage to the sensor at pin 22 on ECU connector (X12). The ECU provides a return ground for the sensor at pin 30 on ECU connector (X12). The exhaust manifold pressure sensor sends an analog signal representing exhaust pressure to pin 52 on ECU connector (X12). For operation of the exhaust manifold pressure sensor, see B5102 - Exhaust Manifold Pressure Sensor . (CTM104919.) Exhaust Gas Recirculation (EGR) Flow Sensor (B5103)— The ECU supplies a 5-volt reference voltage to the sensor at pin 53 on ECU connector (X12). The ECU provides a return ground for the sensor at pin 25 on ECU connector (X12). The EGR flow sensor sends an analog signal representing exhaust gas flow to pin 10 on ECU connector (X12). For operation of the EGR flow sensor, see B5103 - EGR Flow Sensor . (CTM104919.) Intake Manifold Air Pressure (MAP) Sensor (B5104)— The ECU supplies a 5-volt reference voltage to the sensor at pin 53 on ECU connector (X12). The ECU provides a return ground for the sensor at pin 25 on ECU connector (X12). The MAP sensor sends an analog signal representing air pressure to pin 4 on ECU connector (X12). For operation of the MAP sensor, see B5104 - Manifold Air Pressure (MAP) Sensor . (CTM104919.) High-Pressure Fuel Pressure Sensor (B5107)— The ECU supplies a 5-volt reference voltage to the sensor at pin 22 on ECU connector (X12). The ECU provides a return ground for the sensor at pin 30 on ECU connector (X12). The high-pressure fuel pressure sensor sends an analog signal representing fuel pressure to pin 8 on ECU connector (X12). For operation of the high-pressure fuel pressure sensor, see B5107 - High-Pressure Fuel Pressure Sensor . (CTM104919.) Low-Pressure Fuel Pressure Sensor (B5110)— The ECU supplies a 5-volt reference voltage to the sensor at pin 22 on ECU connector (X12). The ECU provides a return ground for the sensor at pin 30 on ECU connector (X12). <- Go to Section TOC
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The low-pressure fuel pressure sensor sends an analog signal representing fuel pressure to pin 13 on ECU connector (X12). For operation of the low-pressure fuel pressure sensor, see B5110 - Low-Pressure Fuel Pressure Sensor . (CTM104919.) Variable Geometry Turbocharger (VGT) Speed Sensor (B5300)— The ECU detects the signal from the VGT speed sensor at pins 29 and 32 on ECU connector (X11). For operation of the VGT speed sensor, see B5300 - VGT Speed Sensor . (CTM104919.) Crankshaft Position Sensor (B5301)— The signal from crankshaft position sensor is used to determine engine speed. The ECU detects the signal from the crankshaft position sensor at pins 30 and 51 on ECU connector (X11). For operation of the crankshaft position sensor, see B5301 - Crankshaft Position Sensor . (CTM104919.) →NOTE: Engine speed can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) Camshaft Position Sensor (B5302)— The ECU detects the signal from the camshaft position sensor at pins 20 and 53 on ECU connector (X11). For operation of the camshaft position sensor, see B5302 - Camshaft Position Sensor . (CTM104919.) For general sensor information, see Measuring Speed . (CTM104919.) For engine protection and derate programs, see Engine Derate and Shutdown Protection . (CTM104919.) Intake Air Sensor (B5500)— The intake air sensor measures compressor inlet pressure as well as temperature of the intake air. The ECU supplies a 5-volt reference voltage to the sensor at pin 41 on ECU connector (X11). The ECU provides a return ground for the sensor at pin 38 on ECU connector (X11). The intake air sensor transmits information across the engine CAN to pins 36 and 45 of ECU connector (X11). →NOTE: The pressure and temperature signals from the intake air sensor can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) A restricted air filter or intake air passage will cause the intake air pressure to drop. The intake air pressure drop across the air intake system can be determined by using a corrected change of barometric pressure and compressor inlet pressure. The ECU contains a barometric pressure sensor and compares the barometric air pressure to the compressor inlet pressure (measured by the intake air sensor) to determine the air flow restriction (air pressure drop). The ECU then compares the data to lookup tables in the ECU and generates a diagnostic trouble code (DTC) at the following thresholds: 6.25 kPa (0.0625 bar) (0.9 psi) for a minimum of 30 seconds. Check Service Code Indicator comes on. 7.50 kPa (0.075 bar) (1.1 psi) for a minimum of 30 seconds. 20% engine deration. Service Required Indicator comes on. 11.00 kPa (0.11 bar) (1.6 psi) for a minimum of 0.5 seconds. 60% engine deration. Stop Indicator comes on. For operation of the intake air sensor, see B5500 - Intake Air Sensor . (CTM104919.) →NOTE: The barometric pressure signal from the ECU can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) Water-In-Fuel (WIF) Sensor (B5600)— The ECU sends 5 volts to the WIF sensor, monitors voltage drop across the sensor at pins 5 and 49 on ECU connector (X11), then compares the voltage drop to preprogrammed values. For operation of the WIF sensor, see B5600 - Water-In-Fuel Sensor . (CTM104919.) Ether Start Aid Solenoid (Y15) (if equipped)— When the engine is cranking and the ECU detects the fuel temperature is below a predetermined temperature, the ECU sends current from pin 46 on ECU connector (X11), energizing the ether start aid solenoid. For more information on the start aid circuit, see Cold Start Aid Circuits Theory of Operation . (Group 9015-15.) Exhaust Gas Recirculation (EGR) Valve Actuator (Y5400)— The ECU controls the EGR valve actuator by sending current out pins 11 and 3 on ECU connector (X11) to pins 4 and 6 on the valve actuator. <- Go to Section TOC
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The EGR valve actuator also contains a feedback position sensor. The ECU supplies a 5-volt reference voltage to the position sensor from pin 53 on ECU connector (X12) and ground from pin 24 on ECU connector (X12). The position sensor then sends a signal representing valve position to the ECU at pin 18 on ECU connector (X12). For operation of the EGR valve actuator, see EGR Valve Operation . (CTM104919.) For component location and connector information, see Y5400 - EGR Valve . (CTM104919.) Air Throttle Valve Actuator (Y5401)— The ECU controls the air throttle valve actuator by sending current out pins 10 and 4 on ECU connector (X11) to pins 4 and 6 on the valve actuator. The air throttle valve actuator also contains a feedback position sensor. The ECU supplies a 5-volt reference voltage to the position sensor from pin 53 on ECU connector (X12) and ground from pin 26 on ECU connector (X12). The position sensor then sends a signal representing valve position to the ECU at pin 12 on ECU connector (X12). For operation of the air throttle valve actuator, see Air Throttle Actuator Operation . (CTM104919.) For component location and connector information, see Y5401 - Air Throttle Actuator . (CTM104919.) The air throttle valve actuator is part of the exhaust filter regeneration process. For more information, see Exhaust Aftertreatment Circuits Theory of Operation . (Group 9015-15.) Variable Geometry Turbocharger (VGT) Actuator (Y5500)— The ECU provides a varying current to the VGT actuator at pins 25 and 31 on ECU connector (X11). For operation of the VGT actuator, see VGT Operation . (CTM104919.) For component location and connector information, see Y5500 — VGT Actuator . (CTM104919.) Low-Pressure Fuel Pump (Y5501)— Unswitched power from fuse (F16) supplies voltage to pin 4 on the pump. The engine interface ground (W30) provides ground to pin 1 on the pump. The ECU sends a power-on signal from pin 50 on ECU connector (X11) to pin 6 on the pump. The low pressure fuel pump transmits information across the engine CAN to pins 36 and 45 on ECU connector (X11). For operation of the low pressure fuel pump, see Low-Pressure Fuel Pump Operation . (CTM104919.) For component location and connector information, see Y5501 - Low-Pressure Fuel Pump . (CTM104919.) Fuel Dosing Pump (Y5502)— Unswitched power from fuse (F15) supplies voltage to pump pin 4 on the pump. The engine interface ground (W30) provides ground to pin 1 on the pump. The ECU sends a power-on signal from pin 17 on ECU connector (X11) to pin 6 on the pump. The fuel dosing pump transmits information across the engine CAN to pins 36 and 45 of ECU connector (X11). For operation of the fuel dosing pump, see Fuel Dosing Pump Operation . (CTM104919.) For component location and connector information, see Y5502 - Fuel Dosing Pump . (CTM104919.) The fuel dosing pump is part of the exhaust aftertreatment system. For operation of the exhaust aftertreatment system, see Exhaust Aftertreatment Circuits Theory of Operation . (Group 9015-15.)
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Engine Control Unit (ECU) Circuit Schematic (3 of 3)
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LEGEND: A3 B5000 B5106 B5108 B5109 B5200 B5204 B5205 B5206 B5207 B5208 B5209 B5511 B5512 B5513 X11 X12 X20 X5001 X5015 X5016 X5023 X5024 Y31 Y32 Y33 Y34 Y35 Y36 Y5000 Y5001
Group 15: Sub-System Diagnostics
Engine Control Unit (ECU) Fuel Dosing Inlet Sensor Fuel Dosing Outlet Pressure Sensor Engine Coolant Pressure Sensor Diesel Particulate Filter (DPF) Differential Pressure Sensor Fixed Turbocharger Compressor Outlet Temperature Sensor Exhaust Filter Temperature Module Charge Air Cooler Outlet Temperature Sensor Manifold Air Temperature (MAT) Sensor Exhaust Gas Recirculation (EGR) Temperature Sensor Engine Coolant Temperature Sensor Fuel Temperature Sensor Diesel Oxidation Catalyst (DOC) Inlet Temperature Sensor Diesel Oxidation Catalyst (DOC) Outlet Temperature Sensor Diesel Particulate Filter (DPF) Outlet Temperature Sensor Engine Control Unit (ECU) Connector (A5501) Engine Control Unit (ECU) Connector (A5502) Engine Interface Harness-to-Exhaust Aftertreatment Harness 6-Pin Connector Engine Control Unit (ECU) Static Ground Engine Interface Harness-to-Engine Harness 40-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Engine Harness-to-Fuel Injectors 6-Pin Connector Engine Harness-to-Fuel Injectors 8-Pin Connector Electronic Unit Injector (EUI) Solenoid (2 used) (cylinder 1) Electronic Unit Injector (EUI) Solenoid (2 used) (cylinder 2) Electronic Unit Injector (EUI) Solenoid (2 used) (cylinder 3) Electronic Unit Injector (EUI) Solenoid (2 used) (cylinder 4) Electronic Unit Injector (EUI) Solenoid (2 used) (cylinder 5) Electronic Unit Injector (EUI) Solenoid (2 used) (cylinder 6) Fuel Dosing Shutoff Valve Fuel Dosing Control Valve
Fuel Dosing Inlet Sensor (B5000)— The fuel dosing inlet sensor is located on the fuel dosing unit. The fuel dose inlet sensor contains two sensors: one for sensing inlet fuel pressure and the other for sensing inlet fuel temperature. For inlet fuel pressure, the ECU sends a 5-volt reference voltage from pin 41 on ECU connector (X12) to pin 3 on the sensor. The ECU provides return ground for the sensor at pin 29 on ECU connector (X12). From pin 4, the sensor sends a signal representing inlet fuel pressure to the ECU at pin 11 on ECU connector (X12). For inlet fuel temperature, the ECU sends 5 volts from pin 32 on ECU connector (X12) to pin 2 on the sensor. The ECU monitors the voltage drop across the temperature sensor at pins 32 and 29 on ECU connector (X12). For operation and location of sensor, see B5000 - Fuel Dosing Inlet Pressure Sensor . (CTM104919.) For operation of dosing unit, see Fuel Dosing Unit Operation . (CTM104919.) The fuel dosing inlet sensor is part of the exhaust filter regeneration process. For more information, see Exhaust Aftertreatment Circuits Theory of Operation . (Group 9015-15.) Fuel Dosing Outlet Pressure Sensor (B5106)— The fuel dosing outlet pressure sensor is located on the fuel dosing unit. The ECU sends a 5-volt reference voltage from pin 41 on ECU connector (X12) to pin 1 on the sensor. The ECU provides return ground for the sensor at pin 29 on ECU connector (X12). The sensor sends a signal representing outlet fuel pressure to the ECU at pin 1 on ECU connector (X12). For operation and location of sensor, see B5106 - Fuel Dosing Outlet Pressure Sensor . (CTM104919.) For operation of dosing unit, see Fuel Dosing Unit Operation . (CTM104919.) The fuel dosing outlet pressure sensor is part of the exhaust filter regeneration process. For more information, see Exhaust Aftertreatment Circuits Theory of Operation . (Group 9015-15.) Engine Coolant Pressure Sensor (B5108)— The ECU supplies a 5-volt reference voltage to the sensor at pin 41 on ECU connector (X12). The ECU provides a return ground for the sensor at pin 31 on ECU connector (X12). The coolant pressure sensor sends an analog signal representing coolant pressure to pin 42 on ECU connector (X12).
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→NOTE: The signal from the engine coolant pressure sensor can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) For operation of the coolant pressure sensor, see B5108 - Engine Coolant Pressure Sensor . (CTM104919.) DPF Differential Pressure Sensor (B5109)— The ECU sends a 5-volt reference voltage to the sensor at pin 41 on ECU connector (X12). The ECU provides return ground for the sensor at pin 31 on ECU connector (X12). The sensor sends a signal representing DPF differential pressure to the ECU at pin 3 on ECU connector (X12). →NOTE: The DPF filter state can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / DIGITAL INPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) →NOTE: The DPF soot and ash load can be viewed as live values by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) For operation of sensor, see B5109 - DPF Differential Pressure Sensor . (CTM104919.) Also see Exhaust Filter Operation . (CTM104919.) For component location, see Exhaust Aftertreatment Harness (W21) Component Location . (Group 9015-10.) The DPF differential pressure sensor is part of the exhaust filter regeneration process. For more information, see Exhaust Aftertreatment Circuits Theory of Operation . (Group 9015-15.) Fixed Turbocharger Compressor Outlet Temperature Sensor (B5200)— The ECU sends 5 volts to the fixed turbocharger compressor outlet temperature sensor, monitors voltage drop across the sensor at pins 16 and 28 on ECU connector (X12), then compares the voltage drop to preprogrammed values. For operation of the fixed turbocharger compressor outlet temperature sensor, see B5200 - Fixed Turbocharger Compressor Outlet Temperature Sensor . (CTM104919.) Exhaust Filter Temperature Module (B5204)— The exhaust filter temperature module is an interface between the ECU and the following sensors located on the exhaust filter assembly: DOC inlet temperature sensor (B5511) DOC outlet temperature sensor (B5512) DPF outlet temperature sensor (B5513) Connections between the ECU and exhaust filter temperature module are as follows: From pin 40 on ECU connector (X11), the ECU provides 12-volt power to pin 3 on the module. From pin 31 on ECU connector (X12), the ECU provides a ground to pin 2 on the module. From pin 41 on ECU connector (X12), the ECU sends a 5-volt reference voltage to pin 1 on the module. The ECU communicates with the module through a data line connected to pin 16 on ECU connector (X11) and pin 4 on the module. →NOTE: The signal from the DPF outlet temperature sensor can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) For operation of module, see B5204 - Exhaust Filter Temperature Module . (CTM104919.) Also see Exhaust Filter Operation . (CTM104919.) For component location, see Exhaust Aftertreatment Harness (W21) Component Location . (Group 9015-10.) The exhaust filter temperature module is part of the exhaust filter regeneration process. For more information, see Exhaust Aftertreatment Circuits Theory of Operation . (Group 9015-15.) Charge Air Cooler Outlet Temperature Sensor (B5205)— The ECU sends 5 volts to the charge air cooler outlet temperature sensor, monitors voltage drop across the sensor at pins 19 and 28 on ECU connector (X12), then compares the <- Go to Section TOC
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voltage drop to preprogrammed values. →NOTE: The signal from the charge air cooler outlet temperature sensor can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) For operation of the charge air cooler outlet temperature sensor, see B5205 - Charge Air Cooler Outlet Temperature Sensor . (CTM104919.) For sensor specifications and characteristics, see Manifold Air Temperature Sensor and Charged Air Cooler Outlet Temperature Sensor Characteristics . (CTM104919.) Manifold Air Temperature (MAT) Sensor (B5206)— The ECU sends 5 volts to the MAT sensor, monitors voltage drop across the sensor at pins 23 and 28 on ECU connector (X12), then compares the voltage drop to preprogrammed values. For operation of the MAT sensor, see B5206 - Manifold Air Temperature (MAT) Sensor . (CTM104919.) For sensor specifications and characteristics, see Manifold Air Temperature Sensor and Charged Air Cooler Outlet Temperature Sensor Characteristics . (CTM104919.) Exhaust Gas Recirculation (EGR) Temperature Sensor (B5207)— The ECU sends 5 volts to the EGR temperature sensor, monitors voltage drop across the sensor at pins 9 and 28 on ECU connector (X12), then compares the voltage drop to preprogrammed values. For operation of the EGR temperature sensor, see B5207 - EGR Temperature Sensor . (CTM104919.) For sensor specifications and characteristics, see EGR Temperature Sensor Characteristics . (CTM104919.) Engine Coolant Temperature Sensor (B5208)— The ECU sends 5 volts to the engine coolant temperature sensor, monitors voltage drop across the sensor at pins 28 and 48 on ECU connector (X12), then compares the voltage drop to preprogrammed values. →NOTE: The signal from the engine coolant temperature sensor can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) For operation of the engine coolant temperature sensor, see B5208 - Engine Coolant Temperature Sensor . (CTM104919.) Fuel Temperature Sensor (B5209)— The ECU sends 5 volts to the fuel temperature sensor, monitors voltage drop across the sensor at pins 28 and 40 on ECU connector (X12), then compares the voltage drop to preprogrammed values. →NOTE: The signal from the fuel temperature sensor can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / ECU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) For operation of the fuel temperature sensor, see B5209 - Fuel Temperature Sensor . (CTM104919.) Electronic Unit Injector (EUI) Solenoids (Y31—Y36)— The ECU controls the EUI solenoids by determining injection timing and amount of fuel needed, then energizes and de-energizes the EUI solenoids as required. Each injector contains two solenoids that are connected to ECU connector (X12) as follows: Cylinder 1 (Y31): Solenoid 1 = pins 24 and 8 Solenoid 2 = pins 35 and 6 Cylinder 2 (Y32): Solenoid 1 = pins 2 and 8 Solenoid 2 = pins 23 and 6 Cylinder 3 (Y33): Solenoid 1 = pins 14 and 8 Solenoid 2 = pins 34 and 6 Cylinder 4 (Y34): Solenoid 1 = pins 15 and 8 Solenoid 2 = pins 33 and 6 <- Go to Section TOC
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Cylinder 5 (Y35): Solenoid 1 = pins 13 and 8 Solenoid 2 = pins 44 and 6 Cylinder 6 (Y36): Solenoid 1 = pins 1 and 8 Solenoid 2 = pins 43 and 6 For operation of the electronic unit injectors, see Electronic Unit Injector (EUI) Operation . (CTM104919.) Fuel Dosing Shutoff Valve (Y5000)— The fuel dosing shutoff valve is an on/off type solenoid valve located on the fuel dosing unit. During filter regeneration, the ECU energizes the solenoid by enabling the high side driver at pin 33 and the low side driver at pin 34 on ECU connector (X12). For operation and location of solenoid valve, see Y5000 - Fuel Dosing Shutoff Valve . (CTM104919.) For operation of dosing unit, see Fuel Dosing Unit Operation . (CTM104919.) The fuel dosing shutoff valve is part of the exhaust filter regeneration process. For more information, see Exhaust Aftertreatment Circuits Theory of Operation . (Group 9015-15.) Fuel Dosing Control Valve (Y5001)— The fuel dosing control valve is located on the fuel dosing unit. During filter regeneration, the fuel dosing control valve is controlled by a pulse width moduled (PWM) signal from pins 35 and 45 on ECU connector (X12). For operation and location of solenoid valve, see Y5001 - Fuel Dosing Control Valve . (CTM104919.) For operation of dosing unit, see Fuel Dosing Unit Operation . (CTM104919.) The fuel dosing control valve is part of the exhaust filter regeneration process. For more information, see Exhaust Aftertreatment Circuits Theory of Operation . (Group 9015-15.)
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Exhaust Aftertreatment Circuits Theory of Operation
Exhaust Aftertreatment Circuits Schematic
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LEGEND: A3 A5 A7 A8 B37 B5000 B5106 B5109 B5204 B5511 B5512 B5513 F15 W30 W33 W34 X5 X9 X11 X12 X13 X14 X16 X20 X21 X22 X23 X29 X5015 X5016 Y7 Y5000 Y5001 Y5401 Y5502
Group 15: Sub-System Diagnostics
Engine Control Unit (ECU) Transmission Control Unit (TCU) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Fuel Level Sensor Fuel Dosing Inlet Sensor Fuel Dosing Outlet Pressure Sensor Diesel Particulate Filter (DPF) Differential Pressure Sensor Exhaust Filter Temperature Module Diesel Oxidation Catalyst (DOC) Inlet Temperature Sensor Diesel Oxidation Catalyst (DOC) Outlet Temperature Sensor Diesel Particulate Filter (DPF) Outlet Temperature Sensor Fuel Dosing Pump 15-Amp Fuse Engine Interface Harness Ground Front Frame Harness Ground Hydraulic Harness Ground Hydraulic Harness-to-Hydraulic Tank Harness 6-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Engine Control Unit (ECU) Connector (A5501) Engine Control Unit (ECU) Connector (A5502) Engine Control Unit (ECU) (A5503) Connector Cab Harness-to-Front Frame Harness 21-Pin Connector Cab Harness-to-Engine Interface Harness 14-Pin Connector Engine Interface Harness-to-Exhaust Aftertreatment Harness 6-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Unswitched Power Terminal) Engine Interface Harness-to-Engine Harness 40-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Dump Body Heat Solenoid Fuel Dosing Shutoff Valve Fuel Dosing Control Valve Air Throttle Valve Actuator Fuel Dosing Pump
System Overview— The exhaust aftertreatment system is controlled by the engine control unit (ECU) (A3). For complete system control, the ECU needs to communicate with the following components via the controller area network (CAN) data line: Transmission Control Unit (TCU) (A5) CAN Monitor Unit (CMU) (A7) Chassis Control Unit (CCU) (A8) For more information on the ECU, CCU, TCU, CMU, and CAN, see the following in Group 9015-15: Engine Control Unit (ECU) Circuits Theory of Operation Chassis Control Unit (CCU) Circuits Theory of Operation Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation Controller Area Network (CAN) Circuit Theory of Operation When the exhaust aftertreatment regeneration process becomes active, the engine idle speed will increase to 1180 rpm, but only if allowed by the machine control system. The CCU will not allow the exhaust aftertreatment system to elevate the engine idle speed when the transmission is in gear. During a stationary regeneration, slow idle speed will increase to 1800 rpm. There are three cleaning processes used to clean the exhaust filter: Auto Cleaning Parked Cleaning Service Cleaning →NOTE: Active regeneration indicator does not illuminate during auto cleaning.
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Auto Cleaning: These processes require no interaction from the operator. When enabled, auto cleaning will activate when exhaust filter restriction is MODERATE or HIGH. With auto cleaning enabled, the CCU will request the ECU to allow elevated idle speed. Elevated idle speed is part of exhaust temperature management where the ECU sets engine speed at 1200 rpm. The ECU prevents the engine speed from going below 1200 rpm until exhaust temperature management is no longer active or automatic filter cleaning is disabled. CCU will command right hand fan speed to 100% for parasitic load induction. For additional information, see Hydraulic Fan Control Circuits Theory of Operation . (Group 9015-05.) For more information on the auto cleaning processes, see Exhaust Filter . (Operator’s Manual.) To enable or disable the auto cleaning processes, see CAN Monitor Unit (CMU)—Main Menu—Exhaust Filter—Auto Cleaning . (Operator’s Manual.) To change default settings for auto cleaning, see CAN Monitor Unit (CMU)—Exhaust Filter . (Group 9015-16.) Parked Cleaning: This process requires activation by the operator when exhaust filter restriction is HIGH or VERY HIGH. The process takes less than 45 minutes to complete. For more information on the parked cleaning process, see Exhaust Filter . (Operator’s Manual.) To activate the parked cleaning process, see CAN Monitor Unit (CMU)—Main Menu—Exhaust Filter—Parked Cleaning . (Operator’s Manual.) Service Cleaning: This process requires activation by the service technician when exhaust filter restriction reaches the SERVICE level. This process is similar to parked cleaning, but requires at least 3 hours to complete. For information and activation of the service cleaning process, see CAN Monitor Unit (CMU)—Exhaust Filter . (Group 9015-16.) Parasitic Load Request— If the exhaust is not hot enough when the filter cleaning process is initiated, the exhaust aftertreatment system will request an additional load be put on the engine to assist in heating the exhaust. To create an extra load, the CCU will command the following: Left side fan to full fan speed. Right side fan set to 50 rpm below full fan speed. For more information on the fan control system, see Hydraulic Fan Control Circuits Theory of Operation . (Group 9015-15.) Electrical Components— The exhaust aftertreatment system uses the following electrical components to monitor and control the exhaust filter cleaning process: Fuel Level Sensor (B37) Fuel Dosing Inlet Sensor (B5000) Fuel Dosing Outlet Pressure Sensor (B5106) Diesel Particulate Filter (DPF) Differential Pressure Sensor (B5109) Exhaust Filter Temperature Module (B5204) Diesel Oxidation Catalyst (DOC) Inlet Temperature Sensor (B5511) Diesel Oxidation Catalyst (DOC) Outlet Temperature Sensor (B5512) Diesel Particulate Filter (DPF) Outlet Temperature Sensor (B5513) Dump Body Heat Solenoid (Y7) (if equipped) Fuel Dosing Shutoff Valve (Y5000) Fuel Dosing Control Valve (Y5001) Air Throttle Valve Actuator (Y5401) Fuel Dosing Pump (Y5502) For information on the engine electrical components, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) Fuel Level Sensor (B37)— The CCU uses the status of the fuel level sensor to prompt the operator when fuel level is less than 12%. At this point, the operator must decide whether to proceed or not with the parked cleaning or service cleaning process. For operation of fuel level sensor, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) Dump Body Heat Solenoid (Y7) (if equipped)— The dump body heat solenoid is part of the optional dump body heat system. For the dump body heat system to function, the following conditions must be met: Body heat option installed and enabled. Engine running for longer than 5 seconds. Dump body position less than or equal to 2%.
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→NOTE: The dump body heat system can be enabled or disabled by accessing the MAIN MENU / SETUP / OPTIONS / MACHINE OPTIONS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Machine Options . (Group 9015-16.) The dump body heat system will automatically deactivate when the transmission is shifted to reverse gear if the INACTIVE IN REVERSE feature is enabled. This feature can be enabled or disabled by accessing the MAIN MENU / SETUP / MACHINE SETTINGS / BODY HEAT submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Machine Settings . (Group 9015-16.) The dump body heat solenoid operates a valve that diverts exhaust flow from the exhaust stack to the dump body when the valve is closed. The valve remains closed during normal operation, but opens during the exhaust filter regeneration process to prevent the dump body from overheating. The valve is cycled between the open and closed positions during the exhaust filter cleaning process. When dump body heat is requested by the operator or the system, the CCU sends current out pin 43 of CCU connector (X22) to the dump body heat solenoid (Y7), energizing the solenoid. With the dump body heat solenoid energized, the valve closes, causing the engine exhaust to circulate through the dump body. If the dump body heating function is enabled and the exhaust filter regeneration is activated, the body heat solenoid will be cycled as follows: If ambient temperature is equal to or more than -10°C (14°F), the CCU closes the valve for 25 seconds by energizing the dump body heat solenoid. It then opens the valve for 5 seconds by de-energizing the solenoid. If ambient temperature is less than -10°C (14°F), the CCU closes the valve for 15 seconds by energizing the dump body heat solenoid. It then opens the valve for 15 seconds by de-energizing the solenoid.
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Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation
Transmission Control Unit (TCU) Circuit Schematic
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LEGEND: A2 A3 A5 A7 A8 A18 B17 B38 B39 B40 B41 B42 B43 F11 F12 F25 R7 W31 W34 X2 X3 X8 X9 X13 X16 X19 X21 X29 X30 X40 X70 X71 X72 X73 X74 Y60 Y61 Y62 Y63 Y64 Y65 Y66 Y67 Y68 Y69 Y70
Group 15: Sub-System Diagnostics
25-Button Sealed Switch Module (SSM) (OC3) Engine Control Unit (ECU) Transmission Control Unit (TCU) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Onboard Weighing (OBW) Controller Transmission Filter Restriction Switch Retarder Temperature Sensor Transmission Sump Temperature Sensor Turbine Speed Sensor Clutch A Primary Speed Sensor Clutch C Secondary Speed Sensor Output Speed Sensor Transmission Control Unit (TCU) Unswitched Power 10-Amp Fuse Service ADVISOR ™ Diagnostic Connector 10-Amp Fuse Transmission Control Unit (TCU) Switched Power 10-Amp Fuse Cab Harness CAN 1 Termination Resistor Cab Ground Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Engine Control Unit (ECU) 54-Pin Connector (A5503) Cab Harness-to-Engine Interface Harness 14-Pin Connector Hydraulic Harness-to-Transmission Control Harness 2-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Fuse Block Unswitched Power Terminal Fuse Block Switched Power Terminal Service ADVISOR™ Diagnostic 9-Pin Connector Transmission Control Unit (TCU) 21-Pin Connector Transmission Control Unit (TCU) 32-Pin Connector Transmission Control Harness-to-Clutch Control Harness 24-Pin Connector Clutch Control Harness-to-Retarder Control Harness 16-Pin Connector Retarder Control Harness-to-Output Speed Sensor 2-Pin Connector Clutch A Solenoid Clutch B Solenoid Clutch C Solenoid Clutch D Solenoid Clutch E Solenoid Clutch F Solenoid Clutch R Solenoid Clutch V Solenoid Torque Converter Lockup (WK) Solenoid Retarder Solenoid Inter-Axle Differential Lock (IDL) Solenoid
Transmission Control →NOTE: The software version, software part number, and hardware part number for the TCU can be accessed in the DIAGNOSTICS / PARTS INFO / STANDARD PARTS / TCU submenu of the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics—Part Info . (Operator’s Manual.) Transmission Control Unit (TCU) (A5)— The TCU controls the transmission by managing operation of proportional solenoid valves to ensure smooth gear and direction transitions. It does this by using the following: Operator command inputs from the 25-button sealed switch module (SSM) (OC3) (A2) via the chassis control unit (CCU) (A8). Inputs received from various sensors hard wired to the TCU. Information from the engine control unit (ECU) (A3). The TCU also receives information from the onboard weighing (OBW) controller (A18) via the chassis control unit (CCU) (A8). Transmission shift duration and timing may vary based on these inputs. <- Go to Section TOC
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The ECU, CCU, and OBW use the controller area network (CAN) to transmit data to the TCU. →NOTE: For more information on the ECU, CCU, OBW, and CAN, see the following located in Group 9015-15: For the CCU circuit, see Chassis Control Unit (CCU) Circuits Theory of Operation . For the ECU circuit and ECU components, see Engine Control Unit (ECU) Circuits Theory of Operation . For the OBW circuit, see Onboard Weighing (OBW) Controller Circuit Theory of Operation For the CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation . The TCU also controls the torque converter lockup clutch and retarder functions. TCU Power-Up (power and ground)— Unswitched power from fuse (F11) is available at pins 2 and 5 on TCU connector (X70). Ground for the TCU is provided by hydraulic harness ground (W34) at pins 1 and 2 on TCU connector (X70). When ignition power is ON, switched current from fuse (F25) flows to pin 8 on TCU connector (X70), powering up the controller. →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) When powered up, the TCU receives and processes information defining: Gear Selection (direction of travel and drive range) Accelerator Pedal Position Engine Speed and Load Turbine Speed Transmission Output Shaft Speed Transmission Sump Temperature Retarder Oil Temperature Percentage of Retardation Slope Percentage (from OBW controller) The TCU uses this information to control the transmission solenoid valves, supply system status, and provide diagnostic information such as diagnostic trouble codes. Diagnostic Trouble Codes— The TCU stores both active and historical DTC codes. An active DTC code is any code that is current in the TCU decision making process. Historical codes are DTC codes that are retained in the TCU′s memory and will not necessarily affect the TCU decision making process. Historical codes are useful in determining if a problem is isolated, intermittent, or results from a previous malfunction. DTC codes can be accessed and cleared using monitor or Service ADVISOR ™ application. Active DTC codes are cleared when power to the TCU is removed. Some codes are self-clearing when the condition that caused the code is no longer detected by the TCU. Other codes must be manually removed. For most transmission related DTC codes, the TCU will send a signal across the CAN data line to the CMU, causing the check service code indicator and/or service required indicator to come on. →NOTE: To diagnose TCU related diagnostic trouble codes, see Transmission Control Unit (TCU) Diagnostic Trouble Codes. (Group 9001-10.) Machine Travel Speed— The CCU calculates machine travel speed using the transmission output shaft speed, axle ratio, and rolling radius of the tire. The CCU receives the output shaft speed data from the TCU via the CAN data line. The CCU uses the output shaft speed data along with the selected tire size and preprogrammed axle ratio to determine travel speed. The CCU transmits the travel speed data to the CMU, where it is displayed on an analog speedometer. →NOTE: The tire size selection can be set by accessing the MAIN MENU / SETUP / OPTIONS / TIRE SIZE OPTIONS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Machine Options . (Group 9015-16.) <- Go to Section TOC
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F (forward), N (neutral), and R (reverse) Switches on 25-Button SSM— When the F, N, and R buttons are pushed and released, the 25-button SSM communicates the button selection to the CCU via the CAN data line. The CCU interprets the button-selection information and sends the appropriate transmission control request across the CAN to the TCU. →NOTE: Transmission gear and direction selections are displayed as live values by accessing the MAIN MENU / DIAGNOSTICS / READINGS / TCU / OTHER INPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—TCU Readings . (Group 9015-16.) Directional controls are as follows: N (neutral): Pushing the N button causes the CCU to send the neutral request across the CAN to the TCU. When the TCU receives this request, it deactivates all transmission control solenoids by not providing any current to the solenoids. Transmission goes to neutral. The CCU then sends the gear data to the CMU, where it appears on the CMU display. R (reverse): Pushing the R button causes the CCU to send the reverse direction request across the CAN to the TCU. When the TCU receives this request, it activates the appropriate solenoids. Once the TCU has activated the solenoids, the TCU communicates to the CCU across the CAN, informing the CCU that the transmission is in a reverse gear. The CCU then sends the gear data to the CMU, where it appears on the CMU display. When in reverse, the CCU will also activate the backup alarm and backup lights. For information on backup alarm and lights, see Backup Alarm and Backup Lights Circuits Theory of Operation . (Group 9015-15.) F (forward): Pushing the F button causes the CCU to send the forward direction request across the CAN data line to the TCU. When the TCU receives this request, it activates the appropriate solenoids. Once the TCU has activated the solenoids, the TCU communicates to the CCU across the CAN, informing the CCU that the transmission is in a forward gear. The CCU then sends the gear data to the CMU, where it appears on the CMU display. Starting Gear: CCU software version 3.00 and earlier— When forward gear is requested, the TCU will command the transmission to start in second gear. If the system determines that a higher torque is needed to efficiently move the machine, the TCU will downshift to first gear. CCU software version 3.01 and later— When forward gear is requested, the TCU will command the transmission to start in first gear. Shuttle Shift Control— The shuttle shift feature allows the transmission to be shifted from forward to reverse or from reverse to forward without requiring the operator to first slow and/or stop the machine. If shuttle shift is commanded when the machine travel speed is more than 3 km/h (2 mph) or when traveling uphill or downhill on a slope equal to or greater than 9%, the retarder will activate at the preset value and the electronic brake valve will apply the service brakes to slow the machine to a safe speed before automatically shifting to the opposite direction. Transmission Filter Restriction Switch (B17)— The transmission filter restriction switch is a normally open switch that is closed when installed and transmission filter is not restricted. The switch opens when filter bypass oil pressure is present (transmission filter restricted). The TCU supplies 6.3 volts at pin 24 on TCU connector (X71) to pin 1 on the oil filter restriction switch. When the switch is closed (transmission filter not restricted), the switch provides 2.2 volts at pin 25 on TCU connector (X71). If the TCU detects the switch is open when the transmission sump temperature is more than 50°C (122°F) and the engine speed is less than 2000 rpm, the TCU will generate a diagnostic trouble code (DTC) and transmit a message across the CAN data line to the CCU. The CCU then forwards the filter restriction information to the CMU, causing the service required light to come on. →NOTE: The transmission filter restriction switch status is displayed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / TCU / DIGITAL INPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—TCU Readings . (Group 9015-16.) Transmission Sump Temperature Sensor (B39)— The TCU sends a reference voltage to the transmission sump temperature sensor, monitors voltage drop across the sensor at pins 27 and 32 on TCU connector (X71), then compares the <- Go to Section TOC
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voltage drop to preprogrammed values. The TCU sends the transmission sump temperature data to the CCU. The CCU uses this information as one of the inputs for controlling fan speed. For more information on fan speed control, see Hydraulic Fan Control Circuits Theory of Operation . (Group 9015-15.) The CCU forwards the transmission sump temperature data to the CMU via the CAN data line, where it is can be displayed in the CMU menus. →NOTE: The transmission sump temperature status is displayed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / TCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—TCU Readings . (Group 9015-16.) If the TCU detects that transmission oil temperature reaches a predetermined specification, the TCU will generate a DTC. If the retarder is engaged, the TCU will decrease current to the retarder solenoid as necessary to reduce oil flow to the retarder. Transmission Warm Up: When the transmission oil temperature is less than 30°C (86°F) at engine startup, the CCU will transmit a CAN message to the ECU requesting engine idle speed to increase to approximately 1180 rpm. If the transmission oil temperature is less than -12°C (10°F), the CCU will prevent the transmission from shifting into gear until the oil temperature reaches the minimal temperature. Turbine Speed Sensor (B40)— The turbine speed sensor is a Hall-effect sensor that provides a signal representing the speed of the input shaft to pins 14 and 15 on TCU connector (X71). TCU uses this information for controlling transmission functions and calibration. →NOTE: The turbine speed is displayed as a live value by accessing the MAIN MENU DIAGNOSTICS / READINGS / TCU / INPUT SENSORS submenu in the CMU menu structure. It is labeled INPUT SHAFT. For TCU input readings, see CAN Monitor Unit (CMU)—TCU Readings . (Group 9015-16.) Clutch A Primary Speed Sensor (B41)— The clutch A primary speed sensor is a Hall-effect sensor that provides a signal representing the speed of clutch A to pins 14 and 16 on TCU connector (X71). The TCU uses the clutch A primary speed sensor for calculating internal speeds for shift control and clutch energy calculations. Clutch C Secondary Speed Sensor (B42)— The clutch C secondary speed sensor is a Hall-effect sensor that provides a signal representing the speed of clutch C to pins 14 and 17 on TCU connector (X71). The TCU uses the clutch C secondary speed sensor for calculating internal speeds for shift control and clutch energy calculations. Output Speed Sensor (B43)— The output speed sensor is a Hall-effect sensor that provides a signal representing the speed of the transmission output shaft to pins 14 and 18 on TCU connector (X71). →NOTE: The transmission output shaft speed is displayed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / TCU / INPUT SENSORS submenu in the CMU menu structure. For TCU input readings, see CAN Monitor Unit (CMU)—TCU Readings . (Group 9015-16.) The TCU uses this information for controlling transmission functions and calibration. The TCU sends the output shaft speed information to the CCU via the CAN data line. The CCU uses this information for controlling other machine control systems. Transmission Control Solenoids (Y60—Y67)— The TCU provides transmission gear selection and travel direction by controlling eight solenoid valves. Each solenoid engages and disengages a corresponding transmission clutch. The TCU modulates the current supplied to the solenoid to control the smoothness of the clutch pack engagement. Y60—Controls first speed clutch pack A. Y61—Controls second speed clutch pack B. Y62—Controls third speed clutch pack C. Y63—Controls fourth speed clutch pack D. Y64—Controls high-range clutch pack E. Y65—Controls low-range clutch pack F. Y66—Controls reverse direction clutch pack R. Y67—Controls forward direction clutch pack V. Forward Gear Selection: The TCU energizes three solenoids at a time to provide eight gear ranges in forward as follows: <- Go to Section TOC
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1st range = solenoids (Y60, Y65, and Y67) 2nd range = solenoids (Y61, Y65, and Y67) 3rd range = solenoids (Y62, Y65, and Y67) 4th range = solenoids (Y63, Y65, and Y67) 5th range = solenoids (Y60, Y64, and Y67) 6th range = solenoids (Y61, Y64, and Y67) 7th range = solenoids (Y62, Y64, and Y67) 8th range = solenoids (Y63, Y64, and Y67) Reverse Gear Selection: The TCU energizes three solenoids at a time to provide four gear ranges in reverse as follows: 1st range = solenoids (Y60, Y65, and Y66) 2nd range = solenoids (Y61, Y65, and Y66) 3rd range = solenoids (Y62, Y65, and Y66) 4th range = solenoids (Y63, Y65), and Y66) For more information on transmission control and clutch engagement, see Transmission Control System and see Transmission Clutch Engagement . (Group 9020-05.) Transmission Clutch Calibration— The TCU provides a means of calibrating the transmission clutches. →NOTE: Transmission calibration is performed by accessing the MAIN MENU / DIAGNOSTICS / CALIBRATIONS / TRANSMISSION submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Calibrations . (Group 9015-16.) The procedure optimizes the clutch pack shift operation by electronically adjusting the TCU for the exact transmission used in the machine. Clutch calibration is required after a transmission is rebuilt or replaced, or after the TCU is replaced. It is also recommended to perform this adjustment after all transmission oil change intervals, including the initial service interval on a new machine or transmission. Gear Hold— Gear hold is activated by pushing the gear hold button on the 25-button SSM. For information on the gear hold button and the SSM, see Sealed Switch Module (SSM) . (Operator’s Manual.) When in gear hold mode, the TCU prevents the transmission from upshifting to a higher range than the range selected at the time of activation. Normal downshifting will occur, but the transmission will not upshift to a higher range until the button is pushed again to disengage gear hold. For more information on gear hold, see Using Gear Hold and Gear Range . (Operator’s Manual.) Torque Converter Lockup (WK) Solenoid (Y68)— The torque converter lockup is a hydraulically applied, spring-release type clutch that, when engaged, puts the transmission into direct drive mode. The TCU provides power to the torque converter lockup solenoid from pin 2 on TCU connector (X71). When conditions call for torque converter lockup, the TCU enables the low-side driver at pin 5 on TCU connector (X71), causing the torque converter lockup solenoid to energize. With the torque converter lockup solenoid energized, pressure oil is allowed to flow to the converter lockup piston. For more information on the torque converter lockup operation, see Torque Converter Operation . (Group 9020-05.) Inter-Axle Differential Lock (IDL) Solenoid (Y70)— The IDL is hydraulically applied, spring released. The TCU provides power to the IDL solenoid from pin 2 on TCU connector (X71). When conditions call for applying the IDL, the TCU enables the driver at pin 12 on TCU connector (X71), energizing the IDL solenoid. For more information on the IDL, see Differential Lock Circuits Theory of Operation . (Group 9015-15.) →NOTE: The status of the IDL can be displayed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / TCU / DIGITAL INPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—TCU Readings . (Group 9015-16.)
Retarder Control The retarder is controlled by the chassis control unit (CCU) (A8), which communicates the retarder request signal across the CAN data line to the TCU. The retarder system is activated whenever the accelerator pedal position is at 2% or less and deactivated when accelerator pedal position is more than 5%. The percentage of retardation that is applied is based on the setting stored in the CCU, except when the service brakes are <- Go to Section TOC
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applied. The percentage of retardation setting can be changed using the retarder control buttons on the 25-button SSM. Changing the retardation setting causes the percentage to briefly display on the CAN monitor unit (CMU) (A7) for 3 seconds. For more information on changing the retardation setting, see Sealed Switch Module (SSM) . (Operator’s Manual.) Retarder Temperature Sensor (B38)— The TCU sends a reference voltage to the retarder temperature sensor, monitors voltage drop across the sensor at pins 21 and 28 on TCU connector (X71), then compares the voltage drop to preprogrammed values. →NOTE: The retarder temperature status is displayed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / TCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—TCU Readings . (Group 9015-16.) If the TCU detects that retarder oil temperature reaches a predetermined specification, the TCU will generate a DTC and send the information to the CMU. The CMU will then display the code. If the retarder is engaged, the TCU will decrease current to the retarder solenoid (Y69) as necessary to reduce oil flow to the retarder. Retarder Solenoid (Y69)— The TCU provides power to the retarder solenoid from pin 2 on TCU connector (X71). When conditions call for retardation, the CCU sends a message representing the percent of retardation to the TCU via the CAN data line. The TCU then pulses the low-side output driver at pin 9 to modulate the retarder solenoid relative to the amount of retardation commanded by the CCU. Whenever the retarder is activated, the CCU will also send a message across the CAN data line to the CMU, causing the retarder indicator to come on. For information on the CMU warning indicators, see CAN Monitor Unit (CMU) and see CAN Monitor Unit (CMU) Functions . (Operator’s Manual.) For operation of the retarder, see Transmission Retarder Operation . (Group 9020-05.) For more information on the retarder and levels of retardation, see Slowing and Stopping the Machine . (Operator′s Manual.) Applying the service brakes causes the service brake light switch to send a signal to the CCU. The CCU communicates this information across the CAN data line to the TCU. The TCU will then activate the retarder at 100%, regardless of the percent of retardation setting. Activation of the retarder also causes the brake lights to come on. For information on the brake lights, see Service Brake Light and Brake Accumulator Low Pressure Circuits Theory of Operation . (Group 9015-15.) Descent Control— The descent control feature uses the retarder to maintain a set speed during downhill operation. Decent control can be set from 10—49 km/hr (6—30 mph). For activation of descent control, see Operating on a Hill . (Operator’s Manual.)
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Chassis Control Unit (CCU) Circuits Theory of Operation
Chassis Control Unit (CCU) Circuits Schematic
<- Go to Section TOC
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LEGEND: A1 A2 A3 A5 A7 A8 A18 A19 A6000 B9 B12 B13 B26 B37 B54 F6 F7 F21 L3 W31 W33 W34 X2 X3 X5 X8 X9 X10 X13 X14 X16 X21 X22 X23 X24 X29 X30 X31 X70 X6014 Y6 Y8
Group 15: Sub-System Diagnostics
15-Button Sealed Switch Module (SSM) (OC4) 25-Button Sealed Switch Module (SSM) (OC3) Engine Control Unit (ECU) Transmission Control Unit (TCU) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Onboard Weighing (OBW) Controller Tire Pressure Monitoring (TPM) System Controller Modular Telematics Gateway (MTG) Hydraulic Filter Restriction Switch Hydraulic Pressure Sensor Secondary Steering Pressure Sensor Articulation Angle Sensor Fuel Level Sensor Hydraulic Temperature Sensor CCU VP2 Unswitched Power 10-Amp Fuse CCU VP3 Unswitched Power 20-Amp Fuse CCU VELX Switched Power 5-Amp Fuse Onboard Weighing (OBW) CAN Filter Cab Ground Front Frame Harness Ground Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Hydraulic Harness-to-Hydraulic Tank Harness 6-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Engine Control Unit (ECU) Connector Cab Harness-to-Front Frame Harness 21-Pin Connector Cab Harness-to-Engine Harness 14-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Chassis Control Unit (CCU) 1-Pin Connector (VP1) Fuse Block Unswitched Power Terminal Fuse Block Switched Power Terminal Cab Harness-to-JDLink™ Harness 12-Pin Connector Transmission Control Unit (TCU) 21-Pin Connector Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector Secondary Steering Test Solenoid (S.N. —XXXXXX) Electronic Brake Valve Solenoid
→NOTE: Whenever the chassis control unit (CCU) is replaced, the new controller must be programmed according to the machine serial number to ensure correct software is installed. →NOTE: The software version, software part number, and hardware part number for the CCU can be accessed in the DIAGNOSTICS / PARTS INFO / STANDARD PARTS / CCU submenu of the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics—Part Info . (Operator’s Manual.) Chassis Control Unit (CCU) (A8)— The CCU monitors and controls the following components, which are discussed in this theory of operation: Hydraulic Filter Restriction Switch (B9) Hydraulic Pressure Sensor (B12) Secondary Steering Pressure Sensor (B13) Articulation Angle Sensor (B26) Fuel Level Sensor (B37) Hydraulic Temperature Sensor (B54) Electronic Brake Valve Solenoid (Y8)
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→NOTE: The secondary steering test solenoid (Y6) is not used. The CCU also monitors and/or controls the following circuits and functions, which are discussed in detail elsewhere in Group 9015-15: Park Brake— See Park Brake Circuit Theory of Operation . Service Brake Lights— See Service Brake Light and Brake Accumulator Low Pressure Circuits Theory of Operation . Dump Body Control— See Dump Body Control and Gear Limit Circuits Theory of Operation . Inter-Axle Differential Lock (IDL)— See Differential Lock Circuits Theory of Operation . Cross-Axle Differential Lock (CDL)— See Differential Lock Circuits Theory of Operation . Axle Cooling and Lubrication Circuits— See Axle Cooling and Lubrication Circuits Theory of Operation . Fan Control— See Hydraulic Fan Control Circuits Theory of Operation . Suspension Height Control— See Suspension Height Control Circuit Theory of Operation . Headlights and Tail Lights— See Headlights and Tail Lights Circuits Theory of Operation . Turn Lights and Four-Way Hazard Warning— See Turn Lights and Four-Way Hazard Lights Circuits Theory of Operation . Backup Alarm and Backup Lights— See Backup Alarm and Backup Lights Circuits Theory of Operation . Work Lights and Rotating Beacon— See Work Lights and Rotating Beacon Circuits Theory of Operation . Stairwell and Service Lights— See Stairwell and Service Lights Circuits Theory of Operation . Horn— See Horn Circuit Theory of Operation . Wipers and Washers— See Windshield Wiper and Washer Circuit Theory of Operation . Electric Mirror— See Electric Mirror Circuit Theory of Operation . Heated Seat— See Heated Seat and Air Seat Compressor Circuits Theory of Operation . Air Seat Control— See Heated Seat and Air Seat Compressor Circuits Theory of Operation . Air Conditioner and Heater— See Air Conditioner and Heater Circuits Theory of Operation . Tire Pressure Monitoring System— See Tire Pressure Monitoring (TPM) System Theory of Operation . Onboard Weighing System— See Onboard Weighing (OBW) Controller Circuit Theory of Operation . Auto Shutdown— See Turbo Spin Down and Auto Shutdown Circuits Theory of Operation . The CCU communicates with the following controllers and components across the CAN 1 data line: 15-Button Sealed Switch Module (SSM) (OC4) (A1) 25-Button Sealed Switch Module (SSM) (OC3) (A2) Engine Control Unit (ECU) (A3) Transmission Control Unit (TCU) (A5) CAN Monitor Unit (CMU) (A7) Modular Telematics Gateway (MTG) (A6000) The CCU communicates with the following controllers across the CAN 2 data line: Onboard Weighing (OBW) Controller (A18) Tire Pressure Monitoring (TPM) System Controller (A19) The operator activates many of the CCU controlled functions using the sealed switch modules (SSM). The SSM is a device that receives operator input through momentary switches. The SSM transmits the switch selections across the CAN 1 data line to the CCU. For more information on the SSM, CMU, and CAN, see the following: For the CMU and SSM circuits, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) For the CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) →NOTE: For information on the other electronic controllers, see the theory of operation of specific component in Group 9015-15. Diagnostic Trouble Codes (DTC)— The CCU provides diagnostics in the form of diagnostic trouble codes for the systems it controls. If a DTC is generated, the condition must be corrected before the DTC can be cleared. For some diagnostic trouble codes, the function must be cycled before the DTC can be cleared. To view and clear diagnostic trouble codes, see CAN Monitor Unit (CMU)—Codes . (Group 9015-16.) Output Drivers and Power Source— The CCU contains high-side output drivers and low-side output drivers. The CCU <- Go to Section TOC
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enables and disables the output drivers as conditions require. When enabled, the high-side output driver provides current to the electrical devices hardwired to the CCU. For those circuits using a low-side output driver, the return current from the electrical device flows back to the CCU to complete the circuit, but only if the low-side output driver is enabled. There are three types of high-side output drivers having a different maximum current output rating as follows: 3.5-Amp 7.0-Amp 14.0-Amp The power source for the CCU outputs comes from power inputs VP1, VP2, and VP3. For more information and a list of all CCU outputs and their associated power sources, see Chassis Control Unit (CCU) Outputs . (Group 9015-20.) CCU Power-Up (Power and Ground)— Unswitched battery power from fuse (F6) is available at pin L1 on CCU connector (X21) to provide VP2 power. Unswitched battery power from fuse (F7) is available at pin 2 on CCU connector (X23) to provide VP3 power. Ground for the CCU is provided by cab ground (W31) at pins L2 and M2 on CCU connector (X21) and pin 2 on CCU connector (X22). Turning ignition power ON causes current to flow through fuse (F21) to pin M1 (VELX) on CCU connector (X21), powering up the CCU. With ignition ON, power becomes available at CCU connector (X24) to provide VP1 power. For switched power and unswitched power circuit information between the battery and the fuses, see 24-Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) System Voltage Monitoring— The CCU has battery monitoring capabilities. The battery voltage can be monitored by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / POWER / BATTERY submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Hydraulic Filter Restriction Switch (B9)— The hydraulic filter restriction switch is a normally closed switch that opens when differential pressure is high. When the hydraulic filter is not restricted, the switch is closed, connecting pin 11 on CCU connector (X23) to ground. A restriction in the hydraulic filter will cause the hydraulic filter restriction switch to open. When the CCU detects an open circuit at pin 11, it will generate a DTC and send a corresponding message across the CAN data line to the CMU, where the information can be displayed. →NOTE: If the hydraulic filter restriction switch is open when the engine is running and the hydraulic oil temperature is less than 0°C (32°F), the CCU will not generate a DTC. →NOTE: The signal from the switch can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) For switch specifications, see Electrical Component Specifications . (Group 9015-20.) Hydraulic Pressure Sensor (B12)— The CCU supplies a 5-volt reference to the sensor at pin E3 on CCU connector (X21). The CCU provides a return ground for the sensor at pin 49 on CCU connector (X22). The hydraulic pressure sensor sends an analog signal representing hydraulic oil pressure to pin 23 on CCU connector (X22). When the CCU detects that the hydraulic pressure signal is outside of normal parameters, it will generate a DTC and send a corresponding message across the CAN data line to the CMU, where the information can be displayed. →NOTE: The signal from the hydraulic pressure sensor can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) For sensor specifications, see Electrical Component Specifications . (Group 9015-20.) Articulation Angle Sensor (B26)— The CCU supplies a 5-volt reference to the sensor at pin E1 on CCU connector (X21). The CCU provides a return ground for the sensor at pin F1 on CCU connector (X21). The articulation angle sensor sends an analog signal representing the angle of articulation to pin 9 on CCU connector (X23). The CCU uses the signal from the articulation angle sensor as part of the differential lock control. For information on the <- Go to Section TOC
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Group 15: Sub-System Diagnostics
differential lock circuit, see Differential Lock Circuits Theory of Operation . (Group 9015-15.) When the CCU detects that the articulation angle signal is outside of normal parameters, it will generate a DTC and send a corresponding message across the CAN data line to the CMU, where the information can be displayed. →NOTE: The signal from the articulation angle sensor can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Articulation Angle Sensor Calibration: Whenever the articulation angle sensor has been replaced or removed and installed, calibration of the sensor must be performed. →NOTE: Calibration of the articulation angle sensor can be performed by accessing the MAIN MENU / DIAGNOSTICS / CALIBRATION / ARTIC ANGLE submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Calibrations . (Group 9015-16.) For sensor specifications, see Electrical Component Specifications . (Group 9015-20.) Fuel Level Sensor (B37)— The fuel level sensor is a variable resistor that provides a varying signal to pin 7 on CCU connector (X23). As fuel level decreases, resistance of the circuit decreases. From the signal, the CCU calculates a value that represents the fuel level and continuously transmits this information across the CAN data line to the CMU. The CMU uses this information to determine the appropriate position of the fuel gauge pointer. →NOTE: The signal from the fuel level sensor can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) For sensor specifications, see Electrical Component Specifications . (Group 9015-20.) Hydraulic Temperature Sensor (B54)— The CCU sends 5 volts to the hydraulic temperature sensor, monitors voltage drop across the sensor at pin 51 on CCU connector (X23) and pin F1 on CCU connector (X21), then compares the voltage drop to preprogrammed values. When the CCU detects that the hydraulic temperature signal is outside of normal parameters, it will generate a DTC and send a corresponding message across the CAN data line to the CMU, where the information can be displayed. →NOTE: The signal from the hydraulic temperature sensor can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) For sensor specifications, see Electrical Component Specifications . (Group 9015-20.) Electronic Brake Valve Solenoid (Y8)— The CCU will energize the electronic brake valve solenoid when any of the following features are enabled and conditions require the automatic activation of the service brakes: Driveline Assist—For operation, see Dump Body Control . (Operator’s Manual.) Load Assist—For operation, see Dump Body Control . (Operator’s Manual.) Hill Hold—For operation, see Operating on a Hill . (Operator’s Manual.) Shuttle Shift—For operation, see Shifting the Transmission . (Operator’s Manual.) Controlled Stop—For operation, see Stopping Engine . (Operator’s Manual.) Electronic activation of the service brakes causes the CCU to send a pulsed width modulated (PWM) signal from pins C1 and G2 on CCU connector (X21) to the electronic brake valve solenoid. The amount of activation of the valve is proportional to the amount of current (percentage of duty cycle) the CCU provides to the solenoid. Increasing the amount of current to the solenoid causes more hydraulic oil to flow to the service brake valve, which in turn, provides more braking force. For hydraulic operation of the electronic brake valve (EBV) and the service brake system, see Service Brake System Operation . (Group 9020-05.)
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Secondary Steering Secondary Steering Pressure Sensor (B13)— The CCU supplies a 5-volt reference to the sensor at pin E3 on CCU connector (X21). The CCU provides a return ground for the sensor at pin 49 on CCU connector (X22). The sensor sends an analog signal representing secondary steering oil pressure to pin 38 on CCU connector (X22). If a significant loss of main hydraulic oil pressure occurs, a valve spool on the secondary steering pump will shift, causing oil from the ground driven secondary steering pump to flow to the steering system. When main hydraulic pressure sensor detects a loss of pressure at the main pump, the CCU sends a CAN message to the CMU, causing the secondary steering indicator to come on. →NOTE: The signal from the secondary steering pressure sensor can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) For more information on the hydraulic operation of the secondary steering system, see Steering and Secondary Steering System Operation and see Secondary Steering Pump Operation . (Group 9025-05.) For sensor specifications, see Electrical Component Specifications . (Group 9015-20.) Secondary Steering Test Solenoid (S.N. —XXXXXX)(Y6)— The secondary steering test solenoid is not used. For information on the hydraulic operation of the secondary steering system, see Steering and Secondary Steering System Operation and see Secondary Steering Pump Operation . (Group 9025-05.) To perform secondary steering test, see Secondary Steering Check . (Group 9005-10.)
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Group 15: Sub-System Diagnostics
CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation
CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Schematic
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LEGEND: A1 A2 A7 A8 F1 F8 F22 F50 G1 H22 K1 S1 V1 W31 X15 X21 X23 X29 X30 X50 X51
Group 15: Sub-System Diagnostics
15-Button Sealed Switch Module (SSM) (OC4) 25-Button Sealed Switch Module (SSM) (OC3) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) SSM-25 and Interior Light 10-Amp Fuse CMU Unswitched Power 10-Amp Fuse CMU and SSM-15 Switched Power 5-Amp Fuse Main 60-Amp Circuit Breaker Battery (2 used) Buzzer Ignition Relay Battery Disconnect Switch Ignition Relay Diode Cab Ground Cab Harness-to-Front Frame Harness 9-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Unswitched Power Terminal Fuse Block Switched Power Terminal Remote Battery Positive Charge Post Remote Battery Negative Charge Post
Sealed Switch Module (SSM) (A1 and A2)— Many of the machine’s electrical systems are controlled using switches located on the 15-button SSM (OC4) (A1) and the 25-button SSM (OC3) (A2). For description and operation of the SSM switches, see Sealed Switch Module (SSM) . (Operator’s Manual.) →NOTE: The software version, software part number, and hardware part number for the 15-button and 25-button SSMs can be accessed in the DIAGNOSTICS / PARTS INFO / STANDARD PARTS submenu of the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics—Part Info . (Operator’s Manual.) The SSMs communicate switch information to the chassis control unit (CCU) (A8) via the controller area network (CAN). For information on the CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) When a switch is pushed, the CCU receives a message from the SSM that identifies the pushed switch. The CCU determines the state of the switch and if the information is valid. It then sends a message back to the SSM to control the relevant LEDs on the switch. The LEDs on each switch indicate the current state of the associated function. If a switch on the SSM becomes stuck in the pressed state, the SSM generates a diagnostic trouble code (DTC) associated with the stuck switch. The function of the stuck switch will go to its default state. Wake-Up Signal— The 25-button SSM provides a wake-up signal to the CCU to activate the hazard lights when the ignition is OFF. Pushing the hazard lights switch on the 25-button SSM when the ignition is OFF causes the 25-button SSM to send a signal out pin 4 on the SSM to pin 19 on CCU connector (X23). When the CCU detects this signal, it sends pulsing current to all the front and rear turn lights. For operation of the hazard lights, see Turn Lights and Four-Way Hazard Lights Circuits Theory of Operation . (Group 9015-15.) SSM Power-Up (power and ground)— The 25-button SSM (A2) receives unswitched battery power from fuse (F1) at pin 1. The cab ground (W31) provides ground to pin 2 on both the 15-button SSM and 25-button SSM. When the engine start switch on the 25-button SSM is pushed and released once, current flows from pin 3 of the 25-button SSM to the coil of ignition relay (K1), energizing the relay. With the ignition relay energized, switched current flows through fuse (F22) to pin 1 on the 15-button SSM, providing power for the 15-button SSM. For more information on switched power and unswitched power circuits, see 24-Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) CAN Monitor Unit (CMU) (A7)— The CMU provides gauges, warning lights, an LCD display, and an audible alarm to indicate machine status. The CMU receives the machine status information from the chassis control unit (CCU) (A8) via the controller area network (CAN). For information on the CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) →NOTE: The software version, software part number, and hardware part number for the CMU can be accessed in the DIAGNOSTICS / PARTS INFO / STANDARD PARTS / CMU submenu of the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics—Part Info . (Operator’s Manual.) <- Go to Section TOC
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Group 15: Sub-System Diagnostics
CMU Menu Structure: Navigation of the CMU menu structure is performed using the four buttons at the right side of the CMU. When a button is pushed, the CMU sends a message to the CCU via the CAN. The CCU then communicates the appropriate response back to the CMU. Pushing the MENU button starts the navigation process, causing menus to appear on the LCD display. The menus are designed for monitoring certain machine functions for operational and/or diagnostic purposes. The menus also provide a means for viewing and clearing diagnostic trouble codes, enabling and disabling options, and adjusting certain machine and monitor settings. For more information on the CMU menu structure, see the following: CAN Monitor Unit (CMU)—Main Menu . (Operator’s Manual.) CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) CMU Power-Up (power and ground)— The CMU receives unswitched battery power from fuse (F8) at pin A. The cab ground (W31) provides ground to the CMU at pin P. When the engine start switch on the 25-button SSM is pushed and released, current flows from pin 3 of the SSM to the coil of ignition relay (K1), energizing the relay. With the ignition relay energized, switched current flows through fuse (F22), to the CMU at pin L, powering up the CMU. For more information on switched power and unswitched power circuits, see 24-Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) When powered up, the CMU initiates a self-test by activating all warning lights, gauges, and the audible alarm. The CMU activates the audible alarm by sending an appropriate pulse width modulated (PWM) signal out pins D and M on the CMU to the buzzer (H22). After the self-test is completed, the default display screen appears and the gauge pointers move to the appropriate position according to machine status. All warning lights are off except the battery charge indicator and park brake indicator. For a description of all monitor warning lights and gauges, see CAN Monitor Unit (CMU) and see CAN Monitor Unit (CMU) Functions . (Operator’s Manual.) If the anti-theft security system is enabled, a security pop-up screen will appear, requiring a valid PIN to be entered. For information on the anti-theft security feature and entering the PIN, see CAN Monitor Unit (CMU)—Main Menu—Security . (Operator’s Manual.)
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Group 15: Sub-System Diagnostics
Dump Body Control and Gear Limit Circuits Theory of Operation
Dump Body Control and Gear Limit Circuits Schematic
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LEGEND: A2 A3 A5 A7 A8 A18 B6 B16 B25 B43 F24 V10 W31 W34 X2 X3 X8 X9 X13 X16 X17 X21 X22 X23 X30 X70 X71 X72 X73 X74 Y8 Y23 Y24 Y25 Y26 Y30
Group 15: Sub-System Diagnostics
25-Button Sealed Switch Module (SSM) (OC3) Engine Control Unit (ECU) Transmission Control Unit (TCU) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Onboard Weighing (OBW) Controller Dump Body Position Sensor Dump Body Lock Switch Dump Body Lever Position Sensor (if equipped) Output Speed Sensor Onboard Weighing (OBW) and Tire Pressure Monitoring (TPM) System 10-Amp Fuse Dump Body Lever Detent Magnet Diode Cab Ground Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Engine Control Unit (ECU) 54-Pin Connector Cab Harness-to-Engine Harness 14-Pin Connector Rear Frame Harness-to-Rear Lights Harness 8-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Switched Power Terminal Transmission Control Unit (TCU) 21-Pin Connector Transmission Control Unit (TCU) 32-Pin Connector Transmission Control Harness-to-Clutch Control Harness 24-Pin Connector Clutch Control Harness-to-Retarder Control Harness 16-Pin Connector Retarder Control Harness-to-Output Speed Sensor 2-Pin Connector Electronic Brake Valve Solenoid Dump Body Down Solenoid Dump Body Up Solenoid Load Holding Pilot Solenoid Dump Body Reduction Solenoid Dump Body Lever Detent Magnet (if equipped)
Dump Body Control System Operation of the dump body control system is controlled by the chassis control unit (CCU) (A8). The CCU continuously monitors the following items, then provides the appropriate signals to the corresponding solenoids for correct dump body operation: SSM Switch Selection Dump Body Lever Position (if equipped) Dump Body Position Dump Body Speed (velocity) Requested Gear (from TCU) Actual Gear (from TCU) Transmission Output Shaft Speed (from TCU) Engine RPM (from ECU) Dump Body Lock Status The CCU uses switched power from VP1 to control the dump body control components. For more information on the CCU and VP1 circuit, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) Dump Body Up and Down Switches— When the dump body up switch is pushed on the 25-button SSM, the SSM sends a message to the CCU via the CAN data line, requesting body up mode. When the CCU determines that the message is valid and all required conditions are met, it will send a signal back to the SSM, causing the LED on the dump body up switch to come on. The CCU will then activate the dump body up solenoid (Y24). For more information, see Dump Body Up Solenoid (Y24) (using 25-button SSM) later in this theory. <- Go to Section TOC
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When the dump body down switch is pushed on the 25-button SSM, the SSM sends a message to the CCU via the CAN data line, requesting body down mode. When the CCU determines that the message is valid and all required conditions are met, it will send a signal back to the SSM, causing the LED on the dump body down switch to come on. The CCU will then activate the dump body down solenoid (Y23). For more information, see Dump Body Down Solenoid (Y23) (using 25-button SSM) later in this theory. →NOTE: For more information on the 25-button SSM, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) For more information on the CAN circuits, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) Dump Body Lever (if equipped)— The dump body lever contains the dump body lever position sensor (B25) and the dump body lever detent magnet (Y30). →NOTE: The dump body lever is an option that must be enabled in the monitor menus for it to function. The dump body lever can be enabled or disabled by accessing the MAIN MENU / SETUP / OPTIONS / CAB OPTIONS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Machine Options . (Group 9015-16.) Dump Body Lever Position Sensor (B25): The CCU provides a 5-volt reference signal and ground to the dump body lever position sensor at pins E1 and F1, respectively, on CCU connector (X21). The CCU monitors the return signal from the dump body lever position sensor at terminal 21 on CCU connector (X23). →NOTE: The status of the dump body lever position sensor input can be viewed as a voltage and a percentage by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) The dump body lever position and operation is as follows: Dump Body Lever Operation Dump Body Status
Lever Position
Voltage at Pin 21 (approximate)
Lower
Full Forward (0%)
0.5 Volts
Neutral
Center (50%)
2.101—2.899 Volts
Raise
Full Rearward (100%)
4.5 Volts
When the CCU receives a request from the dump body lever to raise the dump body and determines that all required conditions are met, the CCU will then activate the dump body up solenoid (Y24). For more information, see Dump Body Up Solenoid (Y24) (using dump body lever) later in this theory. When the CCU receives a request from the dump body lever to lower the dump body and determines that all required conditions are met, the CCU will then activate the dump body down solenoid (Y23). For more information, see Dump Body Down Solenoid (Y23) (using dump body lever) later in this theory. Dump Body Lever Detent Magnet: When energized, the dump body lever detent magnet (Y30) creates a latching mechanism for the dump body lever. The dump body lever will latch when the engine is running, the dump body lever is moved fully forward, and when the dump body position is more than 5%. →NOTE: The status of the dump body lever detent output can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) For sensor specifications, see Electrical Component Specifications . (Group 9015-20.) Dump Body Position Sensor (B6)— The CCU provides a 5-volt reference signal and ground to the dump body position sensor at pins E2 and F2, respectively, on CCU connector (X21). The CCU monitors the return signal from the dump body position sensor at terminal 33 on CCU connector (X23). Calibration of the dump body position sensor must be performed whenever the sensor is removed or replaced. Calibration of <- Go to Section TOC
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the sensor is performed by accessing the MAIN MENU / DIAGNOSTICS / CALIBRATIONS / BODY submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Calibrations . (Group 9015-16.) →NOTE: The status of the dump body position sensor input can be viewed as a voltage and a percentage by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) For sensor specifications, see Electrical Component Specifications . (Group 9015-20.) Dump Body Lock Switch (B16)— The dump body lock switch is a normally open Hall-effect type proximity switch. The switch closes when it detects metal. Fuse (F24) provides a 24-volt reference to pin C on the dump body lock switch. Return ground for the dump body lock switch comes from pin F2 on CCU connector (X21). The CCU monitors the signal from the dump body lock switch at pin 14 on CCU connector (X23). When the dump body lock switch detects metal (lock bar in storage position), the signal to pin 14 is approximately 23 volts. When the dump body lock switch does not detect metal (lock bar in locked position), the signal to pin 14 is approximately 2.2 volts. When the CCU detects only approximately 2.2 volts on pin 14, the CCU will prevent operation of the dump body down function. At the same time it sends a CAN message to the CMU, causing a pop-up message to appear on the CMU display, informing the operator to check the dump body lock bar. →NOTE: In the event that the dump body drifts down while the lock bar is in the locked position, the dump body can be raised using the dump body up function to remove any pressure against the dump body lock bar pin. Dump Body Up Solenoid (Y24) (using 25-button SSM)— When the CCU receives the raise dump body message from the SSM, the CCU enables the high-side and low-side drivers at pins H2 and B4, respectively, on CCU connector (X21). The CCU then sends a pulse width modulated (PWM) signal with a 100% duty cycle from pin H2 to the dump body up solenoid (Y24), energizing the solenoid. The speed of the dump body is controlled by engine speed. During dump body up mode, the CCU will energize the right side fan cut-off solenoid (Y11) to stop hydraulic flow to the right fan motor. This allows more hydraulic flow to go to the dump body up process. For more information on the right side fan cutoff solenoid and fan speed control, see Hydraulic Fan Control Circuits Theory of Operation . (Group 9015-15.) For information on hydraulic control of the dump body up circuit, see Hydraulic System Manifold Operation . (Group 9025-05.) →NOTE: The status of the dump body up solenoid output can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Dump Body Up Solenoid (Y24) (using dump body lever)— When the dump body lever is moved rearward to raise the dump body, the CCU receives a signal from the dump body lever position sensor that is relative to the position of the lever. The CCU will then send a corresponding pulse width modulated (PWM) signal from pin H2 on CCU connector (X21) to the dump body up solenoid (Y24), energizing the solenoid relative to the movement of the lever. The amount of current applied to the dump body up solenoid will determine the amount of movement of the dump body spool valve, and thus control the speed (velocity) of the dump body. →NOTE: The speed of the dump body is also controlled by engine speed. During dump body up mode, the CCU will energize the right side fan cut-off solenoid (Y11) to stop hydraulic flow to the right fan motor. This allows more hydraulic power to go to the dump body up process. For more information on the right side fan cutoff solenoid and fan speed control, see Hydraulic Fan Control Circuits Theory of Operation . (Group 9015-15.) The amount of current to the dump body up solenoid versus dump body lever position is as follows:
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Dump Body Up Solenoid Current Versus Dump Body Lever Position Dump Body Lever Position
Dump Body Up Solenoid (Y24) Current
40—60% (neutral)
0 mA
75%
300 mA
100%
600 mA
For information on hydraulic control of the dump body up circuit, see Hydraulic System Manifold Operation . (Group 9025-05.) If the dump body velocity is greater than 20% and the dump body position is more than 50%, the CCU will determine the dump body is in a “run-away” state. When this occurs, the CCU will decrease the amount of current to the dump body up solenoid to 330 mA for 10 seconds. Dump Body Down Solenoid (Y23) (using 25-button SSM)— When the CCU receives the lower dump body message from the SSM, the CCU enables the high-side and low-side drivers at pins H3 and B4, respectively, on CCU connector (X21). If the dump body position is more than 45%, the CCU sends a pulse width modulated (PWM) signal with a 100% duty cycle from pin H3 to the dump body down solenoid (Y23), energizing the solenoid. The speed of the dump body is controlled by engine speed. If the dump body position is less than 45%, the CCU sends a PWM signal with a 20% duty cycle from pin H3 to the dump body down solenoid (Y23), energizing the solenoid. The reduced current to the dump body down solenoid reduces the speed (velocity) of the dump body. →NOTE: The status of the dump body down solenoid output can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) For information on hydraulic control of the dump body down circuit, see Hydraulic System Manifold Operation . (Group 9025-05.) Dump Body Down Solenoid (Y23) (using dump body lever)— When the dump body lever is moved forward to lower the dump body, the CCU receives a signal from the dump body lever position sensor that is relative to the position of the lever. The CCU will then send a corresponding pulse width modulated (PWM) signal from pin H3 on CCU connector (X21) to the dump body down solenoid (Y23), energizing the solenoid relative to the movement of the lever. The amount of current applied to the dump body down solenoid will determine the amount of movement of the dump body spool valve, and thus control the speed (velocity) of the dump body. →NOTE: The speed of the dump body is also controlled by engine speed. The amount of current to the dump body down solenoid versus dump body lever position is as follows: Dump Body Down Solenoid Current Versus Dump Body Lever Position Dump Body Lever Position
Dump Body Down Solenoid (Y23) Current
40—60% (neutral)
0 mA
25%
300 mA
0%
600 mA (dump body position more than 45%)
If the dump body position is less than 45%, the CCU will energize the dump body down solenoid at a 20% duty cycle. The reduced current to the dump body down solenoid reduces the speed (velocity) of the dump body, regardless of the forward position of the dump body lever. →NOTE: The status of the dump body down solenoid output can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) For information on hydraulic control of the dump body down circuit, see Hydraulic System Manifold Operation . (Group 9025-05.) Load Holding Pilot Solenoid (Y25)— Whenever the CCU activates the dump body up and dump body down solenoids, the <- Go to Section TOC
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CCU also activates the load holding pilot solenoid by sending current from pin 29 of CCU connector (X22). Float mode: The load holding pilot solenoid is deactivated whenever the dump body up and dump body down solenoids are deactivated, except when the dump body angle is 2% or less. When the dump body is at this position, the dump body up and dump body down solenoids are deactivated, but the load holding pilot solenoid stays activated, putting the dump body into float mode. →NOTE: The status of the load holding pilot solenoid output can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) For information on hydraulic control of the dump body, see Hydraulic System Manifold Operation . (Group 9025-05.) Dump Body Reduction Solenoid (Y26)— The dump body reduction solenoid reduces hydraulic pressure to the dump body cylinders to prevent damage to the cylinders when the dump body reaches the fully raised position. The CCU energizes the dump body reduction solenoid (Y26) by enabling the high-side driver at pin F4 on CCU connector (X21) and the low-side driver at pin 33 on CCU connector (X22). →NOTE: The status of the dump body reduction solenoid output can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) For information on hydraulic control of the dump body, see Hydraulic System Manifold Operation . (Group 9025-05.)
Auto Dump Body Operation The auto dump body functions are selected using the auto dump body switch on the 25-button SSM. The auto dump body switch activates the following auto dump body modes as indicated by LEDs on the switch. Each time the switch is pushed and released, it sequences to the next mode. Soft Stop (all LEDs off) Driveline Assist (left LED on) Driveline Assist with Hard Stop (both LEDs on) Hard Stop (right LED on) Soft Stop/Hard Stop: When soft stop or hard stop is active, the CCU monitors the dump body position as it is being raised. Once the dump body reaches a predetermined position (50% for soft stop and 95% for hard stop), the CCU energizes the dump body reduction solenoid (Y26) by enabling the high-side driver at pin F4 on CCU connector (X21) and the low-side driver at pin 33 on CCU connector (X22). The CCU sends a pulse width modulated (PWM) signal to the dump body reduction solenoid. The signal starts out at 0% and incrementally ramps up the duty cycle to 50% as the dump body is raised. The higher the current, the more hydraulic pressure is decreased to the dump body cylinders. The longer ramp up period in soft stop mode allows more time to reduce pressure to the dump body cylinders, resulting in less impact when the dump body reaches its maximum stroke. See Dump Body Reduction Solenoid (Y26) earlier in this theory. Driveline Assist: When driveline assist is selected, the CCU must detect the following for driveline assist to function: Engine running (CAN signal from ECU). Park brake released [signal from park brake pressure switch (B15)]. Transmission output shaft speed less than or equal to 120 rpm [signal from output speed sensor (B43) via CAN signal from TCU]. Service brakes applied [signal from service brake light switch (B24)]. Dump body position less than 97% [signal from dump body position sensor (B6)]. Dump body up switch momentarily pushed or dump body lever (if equipped) moved toward dump body up position. When the conditions previously listed are met, the CCU will command the following: Request and verify that the transmission is shifted to neutral. Request and verify that the electronic brake valve is activated (if enabled in menus).
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→NOTE: Electronic brake valve application with driveline assist can be enabled or disabled by accessing the MAIN MENU / OPERATION / SITE LIMITS / OWNER LIMITS / AUTO DUMP BRAKE submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Operation—Site Limits—Owner Limits . (Group 9015-16.) →NOTE: For operation of the electronic brakes valve, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) Latch dump body up command when dump body up request is received from SSM or dump body lever. Request engine speed to be 2250 rpm. The driveline assist function will stop if any of the following conditions occur: Dump body position is greater than or equal to 97%. Dump body up or down switch is pushed or dump body lever (if equipped) moved in either dump body up or down position. Transmission is shifted into forward or reverse. Dump body position sensor circuit generates a DTC. Engine stop switch on 25-button SSM is pushed. For information on hydraulic control of the dump body, see Hydraulic System Manifold Operation . (Group 9025-05.)
Limitations Site Speed Limit: The CCU monitors the transmission control unit (TCU) (A5) to determine the maximum speed limit. →NOTE: The site speed limit feature can be enabled, disabled, and set by accessing the MAIN MENU / OPERATION / SITE LIMITS / OWNER / SITE SPEED LIMIT submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Operation—Site Limits—Owner Limits . (Group 9015-16.) Body Height Limit: The CCU monitors the transmission control unit (TCU) (A5) to determine what gear the machine is currently in. It then restricts the height that the dump body can be raised. For more information, see Gear Limit Circuit in this theory of operation. →NOTE: The body height limit can be enabled, disabled, and set by accessing the MAIN MENU / OPERATION / SITE LIMITS / OWNER LIMITS / BODY HEIGHT LIMITS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Operation—Site Limits—Owner Limits . (Group 9015-16.) Roll-Over Limit: The CCU monitors the roll percentage sent by the onboard weighing (OBW) controller via the CAN data line. The roll-over limit feature must be enabled in the CMU menus for it to function. When dump body up is requested and the roll percentage is above the preset limit, the CCU will disable the dump body up driver output, preventing activation of the dump body up solenoid (Y24). →NOTE: The roll-over limit feature can be enabled, disabled, and set by accessing the MAIN MENU / OPERATION / SITE LIMITS / OWNER LIMITS / ROLL OVER LIMIT submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Operation—Site Limits—Owner Limits . (Group 9015-16.) Body Restriction: Body restriction limit is defaulted from the factory to be enabled. When the dump body is raised past the 2% position, machine travel speed is limited to 10 km/h (6 mph). This feature will need to be disabled in order to perform certain functions that require a travel speed more than 10 km/h (6 mph). →NOTE: The body restriction feature can be enabled and disabled by accessing the MAIN MENU / OPERATION / SITE LIMITS / OWNER LIMITS / BODY RESTRICTION submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Operation—Site Limits—Owner Limits . (Group 9015-16.) Downhill Tip Limit: The CCU monitors the pitch percentage sent by the OBW controller via the CAN data line. When dump body up is requested while the machine is positioned on a fore-aft incline (rear of machine pointing downhill), the CCU will use the <- Go to Section TOC
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pitch (in degrees) to limit the dump body height. For example, if the machine is on a 10-degree incline, the CCU will tip 10 degrees less than the full tip value selected.
Load Spreading The load spreading feature allows the operator to spread the load over an area at a specific depth. For load spreading operation and instructions, see Dump Body Control . (Operator’s Manual.)
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Differential Lock Circuits Theory of Operation
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Differential Lock Circuits Schematic (1 of 2)
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LEGEND: A2 A4 A5 A7 A8 B26 B43 B58 F36 H22 S5 U1 W33 W34 X2 X3 X8 X9 X10 X14 X21 X22 X23 X55 X56 X70 X71 X72 X73 X74 Y52 Y55 Y70
Group 15: Sub-System Diagnostics
25-Button Sealed Switch Module (SSM) (OC3) Ground Speed Radar Unit Transmission Control Unit (TCU) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Articulation Angle Sensor Output Speed Sensor Front Axle Differential Lock Pressure Sensor Ground Speed Radar 5-Amp Fuse Buzzer Differential Lock Floor Switch 24V to 12V DC Converter Front Frame Harness Ground Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Front Frame Harness 21-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) 24/12V Converter 6-Pin Connector 24/12V Converter 4-Pin Connector Transmission Control Unit (TCU) 21-Pin Connector Transmission Control Unit (TCU) 32-Pin Connector Transmission Control Harness-to-Clutch Control Harness 24-Pin Connector Clutch Control Harness-to-Retarder Control Harness 16-Pin Connector Retarder Control Harness-to-Output Speed Sensor 2-Pin Connector Front Axle Differential Lock Apply Solenoid Front Axle Differential Lock Pressure Regulating Solenoid Inter-Axle Differential Lock (IDL) Solenoid
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Differential Lock Circuits Schematic (2 of 2)
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LEGEND: A8 B15 B59 B60 W34 X2 X3 X9 X21 X22 X23 Y53 Y54 Y56 Y57
Group 15: Sub-System Diagnostics
Chassis Control Unit (CCU) Park Brake Pressure Switch Middle Axle Differential Lock Pressure Sensor Rear Axle Differential Lock Pressure Sensor Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Middle Axle Differential Lock Apply Solenoid Rear Axle Differential Lock Apply Solenoid Middle Axle Differential Lock Pressure Regulating Solenoid Rear Axle Differential Lock Pressure Regulating Solenoid
The differential lock system consists of the inter-axle differential lock (IDL) and the cross-axle differential locks (CDL). The IDL is located in the transmission. The CDL is located in each of the three axles. For the different modes of differential lock operation, see Using Differential Lock . (Operator’s Manual.) Control of the differential lock system involves the 25-button sealed switch module (SSM) (OC3) (A2), chassis control unit (CCU) (A8), transmission control unit (TCU) (A5), and CAN monitor unit (CMU) (A7). These components communicate with each other across the controller area network (CAN). →NOTE: For more information on the CAN circuits, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) For more information on the CCU circuits, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For more information the TCU circuits, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) For more information on the SSM and CMU circuits, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.)
Inter-Axle Differential Lock (IDL) Operation When the IDL is engaged, the torque is evenly split between the front and rear axles. The IDL will engage when any of the following conditions occur: Manually using the IDL switch on the 25-button SSM. Anytime the machine is driven in reverse. Anytime the CDL is activated. Automatically during machine pull-away (ADL enabled). Automatically during wheel slip conditions (ADL enabled). Pushing the IDL switch on the 25-button SSM, causes the SSM to transmit a message across the CAN data line to the CCU, requesting IDL engagement. When the CCU determines that the input is valid, the CCU sends a CAN message back to the 25-button SSM, causing the LED on the IDL switch to come on. The lit LED indicates that the IDL is enabled, but not necessarily engaged. The TCU monitors the transmission output shaft speed by the signal sent by output speed sensor (B43). The TCU transmits the output shaft speed data to the CCU via the CAN data line. When the CCU receives the CAN message from the SSM to engage the IDL, and it detects that the transmission output shaft speed is less than 1480 rpm, the CCU will command the TCU to activate the IDL. Inter-Axle Differential Lock (IDL) Solenoid (Y70): When the TCU receives the command to activate the IDL, the TCU sends current to the inter-axle differential lock (IDL) solenoid, energizing the solenoid. For more information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) If the CCU receives the CAN message from the SSM to engage the IDL and it detects that the transmission output shaft speed is more than 1480 rpm, the CCU will inhibit IDL engagement. The CCU will command IDL engagement when it detects that the output shaft speed has decreased to less than 1380 rpm. <- Go to Section TOC
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When the CCU receives confirmation from the TCU that the IDL has engaged, the CCU will transmit a CAN message to the CMU, causing the IDL indicator to come on and a pop-up message to appear on the CMU display. The buzzer (H22) will beep every 60 seconds during the time the IDL is engaged. →NOTE: The status of the IDL can be displayed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / TCU / DIGITAL INPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—TCU Readings . (Group 9015-16.) IDL Engagement When in Reverse: The CCU will automatically engage the IDL when all of the following conditions are met: Engine running (signal from ECU via the CAN). Transmission shifted into reverse (signal from 25-button SSM via the CAN). Output shaft speed is less than 60 rpm (signal from TCU via the CAN). Park brake is disengaged [signal from park brake pressure switch (B15)]. Articulation angle is less than or equal to 5 degrees [signal from articulation angle sensor (B26)]. →NOTE: For more information on the articulation angle sensor, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.)
When in reverse, the CCU will disengage the IDL when any of the following conditions occur: Transmission shifted to neutral or to forward gear. Output shaft speed is more than 100 rpm. Park brake is engaged. Articulation angle is more than 5 degrees. Engine stopped. IDL Engagement When CDL is Activated: The IDL will engage whenever CDL is activated. For information on CDL activation, see Cross-Axle Differential Lock (CDL) Operation later in this theory. IDL Engagement When ADL is Activated: The IDL will engage whenever auto differential lock (ADL) is activated. For information on ADL activation, see Auto Differential Lock (ADL) Operation later in this theory.
Cross-Axle Differential Lock (CDL) Operation →NOTE: The CCU uses power from VP1 input to provide power to the CDL solenoids. For more information on the VP1 input and CCU outputs, see Chassis Control Unit (CCU) Outputs . (Group 9015-20.) When the CDL is engaged, the torque is evenly split between the left and right wheels. The CDL can be activated manually using a floor-mounted foot switch or automatically when the auto differential lock (ADL) is activated. For ADL operation, see Auto Differential Lock (ADL) Operation later in this theory. Differential Lock Floor Switch (S5)— The differential lock floor switch is a normally open switch located on the cab floor. Pushing the differential lock floor switch connects pin 35 on CCU connector (X23) to the hydraulic harness ground (W34). →NOTE: The status of the differential lock floor switch can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) When the CCU detects ground at pin 35 on CCU connector (X23) and it detects that the transmission output shaft speed data sent by the TCU via the CAN is less than 1400 rpm, the CCU will activate the CDL and IDL solenoids. For information on IDL engagement, see Inter-Axle Differential Lock (IDL) Operation previously in this theory. At the same time, the CCU transmits a CAN message to the CMU, causing the CDL indicator to come on. It also starts an internal timer that sends a CAN message every 30 seconds to the CMU, causing a pop-up message to appear on the CMU display and the buzzer (H22) to beep every 30 seconds while the CDL is engaged. The CDL will disengage if any of the following conditions occur:
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Differential lock floor switch released. Transmission output shaft speed more than 1500 rpm. Engine stopped. If the CDL is disengaged because the speed limit was exceeded, the buzzer will beep and the pop-up message “CDL Speed Limit Exceeded” will appear. If the floor switch is held down and the output shaft speed has decreased to less than 1400 rpm, the pop-up message “CDL Active” will appear on the CMU display and the buzzer will beep. The 30-second timer will reset. Axle Differential Lock Solenoids— When the CCU receives the command to activate the CDL, the CCU sends current out pin D1 on CCU connector (X21) to energize the following solenoids: Front axle differential lock apply solenoid (Y52). Front axle differential lock pressure regulating solenoid (Y55). The CCU also sends current out pin 41 on CCU connector (X22) to energize the following solenoids: Middle axle differential lock apply solenoid (Y53) Middle axle differential lock pressure regulating solenoid (Y56). Rear axle differential lock apply solenoid (Y54) Rear axle differential lock pressure regulating solenoid (Y57). →NOTE: The status of the axle differential lock solenoids outputs can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) When the CDL is not activated (solenoids not energized), the state of the differential lock solenoid valves are as follows: The differential lock apply solenoid valves are closed, blocking oil flow to the differential locks on all three axles. CDL does not apply. The differential lock pressure regulating solenoid valves are open, allowing oil to flow to the axle lube circuit at low pressure. When the CDL is activated (solenoids energized), the state of the differential lock solenoid valves are as follows: The differential lock apply solenoid valves are open, allowing oil to flow to the differential locks on all three axles. CDL applies. The differential lock pressure regulating solenoid valves are closed, blocking the low pressure oil flowing to the axle lube circuit until oil pressure on the differential lock circuit side reaches relief pressure. When this occurs, a relief valve opens and dumps the excess oil flow to the axle lube circuit. The increased oil pressure now available to the differential lock circuit ensures engagement of the differential locks. Item
Measurement
Specification
Differential Lock Pressure Relief (all axles)
Pressure
2827 kPa 28.3 bar 410 psi
Axle Differential Lock Pressure Sensors— Each of the axles has a pressure sensor that provides feedback for the CCU to determine whether the differential lock has the correct pressure when applied. →NOTE: The status of the CDL pressure sensors can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Front Axle Differential Lock Pressure Sensor (B58): The CCU supplies a 5-volt reference to the sensor at pin E1 on CCU connector (X21). The CCU provides a return ground for the sensor at pin F1 on CCU connector (X21). The front axle differential lock pressure sensor sends an analog signal to the CCU at pin 32 on CCU connector (X23). Middle Axle Differential Lock Pressure Sensor (B59): The CCU supplies a 5-volt reference to the sensor at pin E2 on CCU connector (X21). The CCU provides a return ground for the sensor at pin F2 on CCU connector (X21). The middle axle differential lock pressure sensor sends an analog signal to the CCU at pin 44 on CCU connector (X23). Rear Axle Differential Lock Pressure Sensor (B60): The CCU supplies a 5-volt reference to the sensor at pin E2 on CCU <- Go to Section TOC
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connector (X21). The CCU provides a return ground for the sensor at pin F2 on CCU connector (X21). The rear axle differential lock pressure sensor sends an analog signal to the CCU at pin 43 on CCU connector (X23). CDL Indicator and Alarm Activation: When the CDL is activated using the differential floor switch or by the ADL feature, one or both of the following will occur: When the CCU detects a pressure of 1900 kPa (19 bar) (276 psi) or higher from at least one of the differential lock pressure sensors, the CCU will send a CAN message to the CMU, causing the CDL indicator to come on. If the CCU does not detect at least 1900 kPa (19 bar) (276 psi) from any one of the differential lock pressure sensors, the CCU will generate a DTC indicating which CDL is not at pressure. The buzzer will beep and the pop-up message “CDL Fault” will appear on the CMU display. If the CDL is not activated using the differential floor switch or by the ADL feature, and one or more of the differential lock pressure sensors measures a pressure above 1500 kPa (15 bar) (218 psi) for more than 5 seconds, a DTC will be generated and the pop-up message “CDL Fault” will appear on the CMU display.
Auto Differential Lock (ADL) Operation The ADL system operates both the IDL and CDL by using input data from the following: 25-Button Sealed Switch Module (SSM) (OC3) (A2) Ground Speed Radar Unit (A4) Articulation Angle Sensor (B26) Output Speed Sensor (B43) (from TCU via the CAN) The ADL system will automatically apply whenever one of the following occurs: During initial movement of the machine as it pulls away from a stop. In this mode, the system does not use the radar to determine travel speed. When travel speed is approximately 2—20 km/h (1.2—12 mph) and the radar detects wheel slip. When the ADL switch on the 25-button SSM is pushed, the SSM transmits a message across the CAN data line to the CCU requesting auto differential lock. When the CCU determines that the input is valid, the CCU sends a CAN message back to the 25-button SSM, causing the LED on the ADL switch to come on. The lit LED indicates that the ADL is enabled, but not necessarily engaged. Ground Speed Radar Unit (A4)— The ground speed radar unit is a microwave transmitter/receiver that measures frequency shift. The unit contains two antennas (dual-beams) one pointing forward and the other pointing rearward. When ignition power is ON, the 24V to 12V DC converter (U1) supplies 12-volts to pin F on the ground speed radar unit, powering up the unit. For information on 24V to 12V DC converter, see 12-Volt Power Circuits Theory of Operation . (Group 9015-15.) When powered-up, the radar transmitter emits low-powered microwave energy that bounces off the ground. The bounced wave, known as an echo, is detected by the radar receiver. The radar unit compares the difference between the transmitted wave frequency and the received (echo) frequency to determine machine direction and how fast the machine is moving relative to the ground. The radar unit then transmits the data from pin C of the radar unit to the CCU at pin 16 on CCU connector (X22). The CCU compares this data with the data from the articulation angle sensor to provide an offset speed that compensates for when the machine is articulated. To detect wheel slippage, the CCU compares the calculated offset speed with the transmission output shaft speed data received from the TCU via the CAN data line. If wheel slippage is detected for a minimum of 0.5 seconds, the CCU energizes the IDL and CDL solenoids. For IDL solenoid activation, see Inter-Axle Differential Lock (IDL) Operation previously in this theory. For CDL solenoids activation, see Cross-Axle Differential Lock (CDL) Operation previously in this theory.
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Axle Cooling and Lubrication Circuits Theory of Operation
Axle Cooling and Lubrication Circuits Schematic
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LEGEND: A7 A8 B55 B61 B62 B63 B64 B65 B67 B68 B69 H22 W33 W34 X2 X3 X8 X9 X14 X21 X22 X23 Y2
Group 15: Sub-System Diagnostics
CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Rear Axle Pressure Sensor Front Axle Temperature Sensor Middle Axle Temperature Sensor Rear Axle Temperature Sensor Front Axle Pressure Sensor Middle Axle Pressure Sensor Front Axle Filter Restriction Switch Middle Axle Filter Restriction Switch Rear Axle Filter Restriction Switch Buzzer Front Frame Harness Ground Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Front Frame Harness 21-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Axle Cooling Cut-Off Solenoid
Electrical components used for the axles cooling and lubrication system consist of the front, middle, and rear axles temperature sensors, pressure sensors, and filter restriction switches. The system also uses an axle cooling cut-off solenoid for reducing parasitic load on the engine. The chassis control unit (CCU) (A8) monitors signals received from the axle sensors and switches, then transmits the data across the CAN data line to the CAN monitor unit (CMU) (A7). →NOTE: For more information on the CAN circuits, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) For more information on the CCU, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For more information on the CMU, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) Axle Temperature Sensors (B61, B62, and B63)— Each axle has a temperature sensor that measures the brake and axle lubrication oil temperature. The front and middle axle temperature sensors provide brake/axle temperature information that is used in controlling the hydraulic cooling fan system. For information on the hydraulic fan circuit, see Hydraulic Fan Control Circuits Theory of Operation . (Group 9015-15.) →NOTE: The status of the axle temperature sensors can be viewed as voltage and temperature readings by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) The axle temperature readings are labeled in the menus as follows: FNT BRK TEMP MID BRK TEMP REAR AXLE TEMP Front Axle Temperature Sensor (B61): The CCU sends 5 volts to the front axle temperature sensor, monitors voltage drop across the sensor at pin 50 on CCU connector (X23) and pin F1 on CCU connector (X21), then compares the voltage drop to preprogrammed values. When the CCU detects that the temperature signal is outside of normal parameters, it will generate a DTC and send a corresponding message across the CAN data line to the CMU, where the information can be displayed. If the front axle temperature is more than or equal to 83°C (181°F) for 5 seconds or longer, a DTC will be generated, the stop indicator on the CMU will come on, and the buzzer will continuously beep. If the front axle temperature decreases to less than or equal to 81°C (178°F) for a minimum of 3 seconds, the DTC <- Go to Section TOC
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becomes inactive and is stored. For sensor specifications, see Electrical Component Specifications . (Group 9015-20.) Middle Axle Temperature Sensor (B62): The CCU sends 5 volts to the middle axle temperature sensor, monitors voltage drop across the sensor at pin 49 on CCU connector (X23) and pin F2 on CCU connector (X21), then compares the voltage drop to preprogrammed values. When the CCU detects that the temperature signal is outside of normal parameters, it will generate a DTC and send a corresponding message across the CAN data line to the CMU, where the information can be displayed. If the middle axle temperature is more than or equal to 83°C (181°F) for 5 seconds or longer, a DTC will be generated. If the middle axle temperature decreases to less than or equal to 81°C (178°F) for a minimum of 3 seconds, the DTC becomes inactive and is stored. For sensor specifications, see Electrical Component Specifications . (Group 9015-20.) Rear Axle Temperature Sensor (B63): The CCU sends 5 volts to the rear axle temperature sensor, monitors voltage drop across the sensor at pin 48 on CCU connector (X23) and pin F2 on CCU connector (X21), then compares the voltage drop to preprogrammed values. When the CCU detects that the temperature signal is outside of normal parameters, it will generate a DTC and send a corresponding message across the CAN data line to the CMU, where the information can be displayed. If the rear axle temperature is more than or equal to 125°C (257°F) for 5 seconds or longer, a DTC will be generated. If the rear axle temperature decreases to less than or equal to 121°C (250°F) for a minimum of 3 seconds, the DTC becomes inactive and is stored. For sensor specifications, see Electrical Component Specifications . (Group 9015-20.) Axle Pressure Sensors (B55, B64, and B65)— The axle pressure sensors measure lubrication oil pressure flowing to the internal components of the three axles. →NOTE: The status of the axle pressure sensors can be viewed as voltage and pressure readings by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) The axle pressure readings are labeled in the menus as follows: FNT AXLE LUBE MID AXLE LUBE REAR AXLE LUBE Front Axle Pressure Sensor (B64): The CCU supplies a 5-volt reference to the sensor at pin E1 on CCU connector (X21). The CCU provides a return ground for the sensor at pin F1 on CCU connector (X21). The front axle pressure sensor sends an analog signal to the CCU at pin 47 on CCU connector (X23). Middle Axle Pressure Sensor (B65): The CCU supplies a 5-volt reference to the sensor at pin E2 on CCU connector (X21). The CCU provides a return ground for the sensor at pin F2 on CCU connector (X21). The middle axle pressure sensor sends an analog signal to the CCU at pin 22 on CCU connector (X23). Rear Axle Pressure Sensor (B55): The CCU supplies a 5-volt reference to the sensor at pin E2 on CCU connector (X21). The CCU provides a return ground for the sensor at pin F2 on CCU connector (X21). The rear axle pressure sensor sends an analog signal to the CCU at pin 45 on CCU connector (X23). Axle Lubrication Pressure Alarm: If the lubrication oil pressure decreases to less than 275 kPa (2.75 bar) (40 psi) for more than 10 seconds from any one of the axle pressure sensors when the following conditions are met: Engine running. Transmission in gear (not neutral). Axle cut-off disabled. Then the following will occur: Stop indicator on CMU will come on. Buzzer will continuously beep. DTC is generated. Pop-up message “Low Axle Lube Pressure/Vehicle Protection Mode” appears on CMU display. Machine travel speed is limited to 7 km/h (4 mph). <- Go to Section TOC
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When the lubrication oil pressure increases to more than 300 kPa for more than 10 seconds, the DTC becomes inactive, travel speed restriction is lifted, and the pop-up message on the CMU display is cleared. For sensor specifications, see Electrical Component Specifications . (Group 9015-20.) Axle Filter Restriction Switches (B67, B68, and B69)— The axle filter restriction switches are normally closed switches that open when differential pressure is high (filter restricted). →NOTE: The status of the axle filter restriction switches can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Front Axle Filter Restriction Switch (B67): When the front axle filter is restricted, pin 46 on CCU connector (X23) is disconnected from the front frame harness ground (W33). When the CCU detects the open signal at pin 46, it will generate a DTC and send a corresponding message across the CAN data line to the CMU, where the information can be displayed. Middle Axle Filter Restriction Switch (B68): When the middle axle filter is restricted, pin 34 on CCU connector (X23) is disconnected from the hydraulic harness ground (W34). When the CCU detects the open signal at pin 34, it will generate a DTC and send a corresponding message across the CAN data line to the CMU, where the information can be displayed. Rear Axle Filter Restriction Switch (B69): When the rear axle filter is restricted, pin 10 on CCU connector (X23) is disconnected from the hydraulic harness ground (W34). When the CCU detects the open signal at pin 10, it will generate a DTC and send a corresponding message across the CAN data line to the CMU, where the information can be displayed. For switch specifications, see Electrical Component Specifications . (Group 9015-20.) Axle Cooling Cut-Off Solenoid (Y2)— The CCU will energize the axle cooling cut-off solenoid to reduce parasitic load on the engine during cranking or to recover from a near-stall condition. During engine start-up or a near-stall condition, the CCU sends current from pin 44 on CCU connector (X22) to the axle cooling cut-off solenoid (Y2), energizing the solenoid. The energized solenoid prevents hydraulic flow to the axle cooling hydraulic motor.The CCU will de-energize axle cooling cut-off solenoid once transmission output speed has been detected. →NOTE: The status of the axle cooling cut-off solenoid output can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) For more information, see Hydraulic System Manifold Operation . (Group 9025-05.)
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Hydraulic Fan Control Circuits Theory of Operation
Hydraulic Fan Control Circuits Schematic
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LEGEND: A3 A5 A7 A8 B7 B8 B27 B39 B54 B61 B62 B5206 B5208 B5301 V4 V7 V8 W33 W34 X2 X3 X5 X8 X9 X10 X11 X12 X13 X14 X16 X21 X22 X23 X32 X33 X70 X71 X72 X73 X5015 X5016 Y9 Y11 Y22 Y48 Y49 Y50 Y51 Y71
Group 15: Sub-System Diagnostics
Engine Control Unit (ECU) Transmission Control Unit (TCU) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Left Fan Speed Sensor Right Fan Speed Sensor Air Conditioner High/Low Pressure Switch Transmission Sump Temperature Sensor Hydraulic Temperature Sensor Front Axle Temperature Sensor Middle Axle Temperature Sensor Manifold Air Temperature (MAT) Sensor Engine Coolant Temperature Sensor Crankshaft Position Sensor Air Conditioner Compressor Clutch Diode Left Side Reversing Fan Solenoid Diode Right Side Reversing Fan Solenoid Diode Front Frame Harness Ground Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Hydraulic Harness-to-Hydraulic Tank Harness 6-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Engine Control Unit (ECU) Connector (A5501) Engine Control Unit (ECU) Connector (A5502) Engine Control Unit (ECU) Connector (A5503) Cab Harness-to-Front Frame Harness 21-Pin Connector Cab Harness-to-Engine Harness 14-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Air Conditioner High/Low Pressure Switch 1-Pin Connector Air Conditioner High/Low Pressure Switch 1-Pin Connector Transmission Control Unit (TCU) 21-Pin Connector Transmission Control Unit (TCU) 32-Pin Connector Transmission Control Harness-to-Clutch Control Harness 24-Pin Connector Clutch Control Harness-to-Retarder Control Harness 16-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Engine Interface Harness-to-Engine Harness 40-Pin Connector Left Side Fan Speed Solenoid Right Side Fan Cut-Off Solenoid Air Conditioner Compressor Clutch Left Side Fan Low Pressure Solenoid Right Side Fan Low Pressure Solenoid Left Side Reversing Fan Solenoid Right Side Reversing Fan Solenoid Right Side Fan Speed Solenoid
Hydraulic Fan System Overview The hydraulic fan system consists of a left side fan and a right side fan that provides cooling for the following: Left Side Fan Left Radiator Air Conditioner Condenser Service Brakes and Axle Oil Charge Air Right Side Fan Right Radiator Transmission Oil Hydraulic Oil Fuel Cooler The hydraulic fan system is controlled by the chassis control unit (CCU) (A8). The CCU monitors input data from sensors <- Go to Section TOC
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hardwired to the CCU. The CCU also monitors data broadcast across the controller area network (CAN) from the following controllers: Engine control unit (ECU) (A3). For more information, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) Transmission control unit (TCU) (A5). For more information, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) The CCU communicates much of the fan related sensor information to the CAN monitor unit (CMU) (A7), where it can be displayed in the CMU menus. For more information on the CMU, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) For more information on the CCU, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For operation of the CAN, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) The CCU automatically controls the speed of the fans by monitoring the following inputs: Fan Speed Retarder Torque Hydraulic Temperature Air Conditioner ON/OFF Status Front and Middle Axle Temperatures Engine Speed (from ECU via CAN) Manifold Air Temperature (from ECU via CAN) Engine Coolant Temperature (from ECU via CAN) Transmission Temperature (from TCU via CAN) Exhaust Filter Cleaning Request The input calling for the highest fan speed will be the controlling parameter. The maximum allowable fan speed is dependent on engine speed. When the CCU determines the target speed for each fan, it provides the appropriate pulse width modulated (PWM) signal to the fan speed solenoids. The amount of current the CCU sends to each fan speed solenoid is inversely dependent on the calculated fan speed. Minimum current commands maximum fan speed. Each fan speed solenoid controls a proportional valve which, in turn, controls the amount of oil flow through the corresponding cooling fan motor. For hydraulic information of fan control, see Fan Drive System Operation . (Group 9025-05.) Fan Drive State— The fan drives have three states of operation: Initial State (Ignition ON/Engine OFF): When the ignition power is turned ON, the CCU commands the fan speed solenoid output drivers as follows: Left and right fan speed solenoid output drivers are commanded to zero current output. Fan cut-off solenoid output driver is disabled. Fan Off State (Engine START): When engine start sequence is activated, the CCU provides the least possible parasitic load to the engine by commanding the fan speed solenoid output drivers as follows: Left and right fan speed solenoid output drivers are commanded to the minimum output of 600 mA. The CCU will adjust the output until the fan speed has achieved 600 rpm. That output is used for minimum fan speed output until the ignition is cycled. Fan cut-off solenoid output driver is enabled, energizing the right side fan cut-off solenoid (Y11). This disables the right side fan by stopping hydraulic flow to the right fan motor during engine start. Normal State (Engine Running): When the CCU detects that the engine is running and no fan related diagnostic trouble codes are present, the CCU will provide normal closed loop speed control to both fans. Fan Speed Control— The fan speed control system in the CCU uses a lookup table to determine the approximate current to send to the fan speed solenoids to obtain the target fan speed. The lookup table provides default currents at three calibrated fan speeds. All currents between these set points are linearly scaled. The three calibrated fan speed set points are shown in the Fan Speed Control Range table. To minimize fan speed error, the fan speed control system uses a closed loop speed control function, provided by the fan speed sensors, to continuously calculate an offset current value. The fan speed sensors provide a measured fan speed to the CCU that may differ from the commanded fan speed determined by the lookup table. The fan speed control system combines the offset current value with the current provided by the lookup table, then sends the adjusted current to the fan speed solenoids. <- Go to Section TOC
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If the offset current value becomes too large, the fan speed control system will enable an inhibit function that will calculate the offset current based on values established immediately prior to the inhibit function being enabled. The fan speed control system enables the inhibit function if any one of the following conditions occur: Right side fan cut-off solenoid (Y11) energized. Hydraulic power to right side fan motor is disabled. Commanded fan speed greater than 1500 rpm when engine speed is less than 1400 rpm. Commanded fan speed is outside the speed control range. Fan Speed Control Range: The fan speed control range is defined as the range between (and including) the minimum fan speed and the maximum operating fan speed as shown in the following table: Fan Speed Control Range Fan Speed Control Range Speed Control Range
Description
Estimated Current Fan Speed
Minimum Fan Speed
Slowest speed that can be reliably obtained with engine speed at fast idle.
600 mA
600 rpm
Full Fan Speed
Fan speed providing sufficient cooling capacity for sustained operation in worst case ambient conditions.
132 mA
2025 rpm
Maximum Operating Speed—Right Fan
Maximum fan speed that can be reliably obtained at engine speeds greater than 1500 rpm.
60 mA
1930 rpm
Maximum Operating Fan Speed—Left Fan
When engine speed is at fast idle and zero current is available to the fan speed solenoid, the fan will go to the maximum uncontrolled fan speed. The zero current condition can be caused by an open or short circuit in the fan speed solenoid circuit. Parasitic Load Control— During certain system operations, the fan control system will either reduce or induce a parasitic load on the engine and hydraulic system. Parasitic Load Reduction: The right side fan cut-off solenoid (Y11) is used to reduce the parasitic load on the engine and hydraulic system by stopping hydraulic flow to the right fan motor during the following situations: Engine start. Dump body up mode. Machine shutdown. Transmission Calibration →NOTE: For more information on fan cut-off operation during engine start, see Start and Charge Circuits Theory of Operation . (Group 9015-15.) For more information on fan cut-off operation during dump body up mode, see Dump Body Control and Gear Limit Circuits Theory of Operation . (Group 9015-15.) If the CCU detects an open circuit or short to ground on the right side fan cut-off solenoid circuit, the CCU will command the right fan to run at minimum fan speed. Parasitic Load Induction: If the exhaust is not hot enough when the filter cleaning process is initiated, the exhaust aftertreatment system will request an additional load be put on the engine to assist in heating the exhaust. To create an extra load, the CCU will command the following: Left side fan to full fan speed. →NOTE: CCU commands right fan to full fan speed during exhaust filter cleaning. For additional information, see Exhaust Aftertreatment Circuit Theory of Operation . (Group 9015-05.) Right side fan set to 50 rpm below full fan speed. Elevated engine idle speed of 1200 rpm Fan Shutdown— When a machine shutdown sequence is initiated, the CCU remains powered to provide the following sequence of events: 1. The CCU sends 600 mA to both left and right fan speed solenoids (Y9 and Y71) to ramp down to minimum fan speed. 2. The CCU uses the input signal from both left and right fan speed sensors (B7 and B8) to verify that both fans are within 50 rpm of minimum fan speed. The CCU will wait until this condition is met. 3. The CCU then sends the maximum allowable current of 800 mA to the left side fan speed solenoid (Y9). <- Go to Section TOC
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4. The CCU energizes the right side fan cut-off solenoid (Y11) to stop hydraulic flow to the right fan motor. 5. The CCU energizes the left and right side fan low pressure solenoids (Y48 and Y49). The energized solenoids slowly dump pressure oil to tank to allow the fans to coast to a stop. For hydraulic information on fan speed control, see Fan Drive System Operation . (Group 9025-05.) →NOTE: When the fan shutdown is complete and all other shutdown sequences have been performed, the CCU will power down.
Left Side Fan Speed Control The CCU determines the target speed of the left side fan by the ON/OFF status of the air conditioner compressor output and information received from the following components: Left Fan Speed Sensor (B7) Front Axle Temperature Sensor (B61) Middle Axle Temperature Sensor (B62) Manifold Air Temperature (MAT) Sensor (B5206) (from ECU via CAN) Crankshaft Position Sensor (B5301) (from ECU via CAN) Left Fan Speed Sensor (B7)— The left fan speed sensor is a Hall-effect sensor that is hard-wired to the CCU. The CCU supplies a 5-volt reference to the sensor from pin E1 on CCU connector (X21). The CCU provides a return ground for the sensor at pin F1 on CCU connector (X21). The sensor sends an analog voltage signal representing fan speed to pin 27 on CCU connector (X22). The CCU uses the signal from the left fan speed sensor for closed loop speed control of the left side fan. If an open or short occurs in the fan speed sensor circuit, the CCU will cause the fan to go to maximum fan speed. →NOTE: The left fan speed sensor data can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Front Axle Temperature Sensor (B61)— The front axle temperature sensor provides front axle lubrication and brake oil temperature information. For electrical information on the axle cooling and lubrication circuit, see Axle Cooling and Lubrication Circuits Theory of Operation . (Group 9015-15.) The CCU sends 5 volts to the front axle temperature sensor, monitors voltage drop across the sensor at pin 50 on CCU connector (X23) and pin F1 on CCU connector (X21), then compares the voltage drop to preprogrammed values. If the CCU determines that front axle oil temperature is the controlling parameter calling for the highest fan speed, then the CCU will increase the left side fan speed accordingly. →NOTE: The status of the front axle temperature sensor can be viewed as voltage and temperature readings by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) The front axle temperature reading is labeled in the menu as FNT BRK TEMP. For sensor specifications, see Electrical Component Specifications . (Group 9015-20.) Middle Axle Temperature Sensor (B62)— The middle axle temperature sensor provides middle axle lubrication and brake oil temperature information. For electrical information on the axle cooling and lubrication circuit, see Axle Cooling and Lubrication Circuits Theory of Operation . (Group 9015-15.) The CCU sends 5 volts to the middle axle temperature sensor, monitors voltage drop across the sensor at pin 49 on CCU connector (X23) and pin F2 on CCU connector (X21), then compares the voltage drop to preprogrammed values. If the CCU determines that middle axle oil temperature is the controlling parameter calling for the highest fan speed, then the CCU will increase the left side fan speed accordingly.
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→NOTE: The status of the middle axle temperature sensor can be viewed as voltage and temperature readings by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) The front axle temperature reading is labeled in the menu as MID BRK TEMP. For sensor specifications, see Electrical Component Specifications . (Group 9015-20.) Manifold Air Temperature (MAT) Sensor (B5206)— The MAT sensor is hard-wired to the ECU. The ECU determines the manifold air temperature from this signal and continuously broadcasts the manifold air temperature data to the CCU via the CAN data line. If the CCU determines that manifold air temperature is the controlling parameter calling for the highest fan speed, then the CCU will increase the left side fan speed accordingly. For more information on the manifold air temperature sensor and the ECU, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) Crankshaft Position Sensor (B5301)— The crankshaft position sensor is hard-wired to the ECU. The ECU determines the engine speed from this signal and continuously broadcasts the engine speed data to the CCU via the CAN data line. The CCU uses the engine speed information to determine when engine running state occurs, then sets the fan speed as conditions require. For more information on the crankshaft position sensor and the ECU, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) Air Conditioner ON/OFF Status— The air conditioner compressor clutch (Y22) is hard-wired to the CCU via air conditioner high/low pressure switch (B27). The CCU continuously monitors the output to the air conditioner compressor clutch. If the air conditioner output is enabled and the CCU determines that it is the controlling parameter calling for the highest fan speed, then the CCU will increase the left side fan speed accordingly. For more information on the air conditioner compressor clutch circuit, see Air Conditioner and Heater Circuits Theory of Operation . (Group 9015-15.)
Right Side Fan Speed Control The CCU controls fan speed based on the component with the highest requested parameter received from the following components: Hydraulic Temperature Sensor (B54) Transmission Sump Temperature Sensor (B39) (from TCU via CAN) Retarder Temperature Sensor (B38) (from TCU via CAN) Engine Coolant Temperature Sensor (B5208) (from ECU via CAN) Right Fan Speed Sensor (B8)— The right fan speed sensor is a Hall-effect sensor that is hard-wired to the CCU. The CCU supplies a 5-volt reference to the sensor from pin E1 on CCU connector (X21). The CCU provides a return ground for the sensor at pin F1 on CCU connector (X21). The sensor sends an analog voltage signal representing fan speed to pin 50 on CCU connector (X22). The CCU uses the signal from the right fan speed sensor for closed loop speed control of the right side fan. →NOTE: The right fan speed sensor data can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SENSORS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Hydraulic Temperature Sensor (B54)— The hydraulic temperature sensor is hard-wired to the CCU. If the CCU determines that hydraulic oil temperature is the controlling parameter calling for the highest fan speed, then the CCU will increase the right side fan speed accordingly. For more information on the hydraulic temperature sensor and the CCU, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) Transmission Sump Temperature Sensor (B39)— The transmission sump temperature sensor is hard-wired to the TCU. The TCU continuously broadcasts the transmission sump oil temperature data to the CCU via the CAN data line. If the CCU determines that transmission sump oil temperature is the controlling parameter calling for the highest fan speed, then the CCU will increase the right side fan speed accordingly. <- Go to Section TOC
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For more information on the transmission sump temperature sensor and the TCU, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) Engine Coolant Temperature Sensor (B5208)— The engine coolant temperature sensor is hard-wired to the ECU. The ECU determines the coolant temperature from this signal and continuously broadcasts the coolant temperature data to the CCU via the CAN data line. If the CCU determines that engine coolant temperature is the controlling parameter calling for the highest fan speed, then the CCU will increase the right side fan speed accordingly. For more information on the engine coolant temperature sensor and the ECU, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) Crankshaft Position Sensor (B5301)— The crankshaft position sensor is hard-wired to the ECU. The ECU determines the engine speed from this signal and continuously broadcasts the engine speed data to the CCU via the CAN data line. The CCU uses the engine speed information to determine when engine running state occurs, then sets the fan speed as conditions require. For more information on the crankshaft position sensor and the ECU, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) Retarder Control— When active, the transmission retarder puts an immediate demand on the cooling system associated with the right side fan. The CCU contains a retarder activity timer. The timer will count up to a maximum of 10 seconds whenever the actual retarder torque is equal to or greater then 20%. When the counter reaches 10 seconds, the CCU will command the right side fan to full speed. The CCU will keep the fan at full speed for as long as the timer value is equal to or greater than 7 seconds. When the actual retarder torque is less than 10%, the counter will count down to a minimum of 0 seconds. When the timer value drops below 7 seconds, the CCU will use the calculation of the temperature inputs to control the right side fan speed. Right Side Fan Speed Calculation— The CCU calculates the target speed for the right side fan by readings it receives from the hydraulic oil temperature sensor, transmission sump oil temperature sensor, and engine coolant temperature sensor. The input calling for the highest fan speed will be the controlling parameter. The temperature control ranges versus fan speed are as follows: Hydraulic Oil Temperature 90°C (194°F) = Minimum speed (600 rpm) 100°C (212°F) = Full speed (1813 rpm) Transmission Sump Oil Temperature 90°C (194°F) = Minimum speed (600 rpm) 100°C (212°F) = Full speed (1813 rpm) Engine Coolant Temperature 90°C (194°F) = Minimum speed (600 rpm) 110°C (230°F) = Full speed (1813 rpm) The fan speeds are linearly scaled between the minimum speed and full speed limits of the temperature control range. For example: If the temperature control range is from 90°C to 100°C (194°F to 212°F) and the actual temperature is 95°C (203°F), the fan speed command will be halfway between minimum and full speed. In this case, 95°C (203°F) will command the fan speed to 1215 rpm.
Fan Reverse Control (If Equipped) The fan reverse function changes the fan direction to purge the cooling system of debris. The CCU automatically displays a prompt on the CMU screen to inform the operator to change fan direction every 1, 2, 3, 8, or 12 hours, depending on cycle time selected in the CMU submenu. →NOTE: The time interval since last fan reversing cycle can be changed by accessing the MAIN MENU / SETUP / FAN REV REMINDER submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Setup—Fan Reverse Reminder . (Operator’s Manual.) The fan reversing process is initiated by accessing the MAIN MENU / OPERATION / REVERSE FAN submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Operation—Reverse Fans . (Operator’s Manual.) The following conditions must be met to activate the fan reversal. <- Go to Section TOC
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Transmission in neutral. Park brake engaged. Engine running at slow idle. Hydraulic oil at normal operating temperature. Reversing Operation— When the operator initiates the fan reverse process, the CCU begins the reversing sequence as follows: [1] - The CCU commands the engine speed to increase to 1650 rpm. [2] - The CCU ramps up the current to the left side fan speed solenoid (Y9) to slow the left fan to minimum fan speed—approximately 600 rpm. The right side fan remains in normal operating mode. [3] - The CCU then energizes the left side fan low pressure solenoid (Y48). The energized solenoid slowly dumps pressure oil to tank to allow the fan to coast to a stop. [4] - When the left side fan reaches minimum speed, the CCU sends current out terminal K1 of CCU connector (X21) to the left side reversing fan solenoid (Y50), energizing the solenoid. This causes the left side fan to reverse direction. [5] - With the left side fan now operating in the reverse direction, the CCU de-energizes the left side fan low pressure solenoid (Y48) and ramps down the current to the left side fan speed solenoid (Y9) until the left side fan speed reaches full speed in reverse—approximately 1813 rpm—for 25 seconds. The right side fan remains in normal operating mode. [6] - After the 25 seconds has elapsed, the CCU then ramps up the current to the left side fan speed solenoid (Y9) until the fan is at minimum speed again, then energizes the left side fan low pressure solenoid (Y48). [7] - When the left side fan reaches minimum speed, the CCU de-energizes the left side reversing fan solenoid (Y50). This causes the left side fan to change back to forward direction. [8] - With the left side fan operating in the forward direction, the CCU de-energizes the left side fan low pressure solenoid (Y48) and ramps down the current to the left side fan speed solenoid (Y9) to return the left side fan to normal operating mode. [9] - The CCU then ramps up the current to the right side fan speed solenoid (Y71) to slow the right fan to minimum fan speed—approximately 600 rpm. The left side fan remains in normal operating mode. [10] - The CCU then energizes the right side fan low pressure solenoid (Y49). The energized solenoid slowly dumps pressure oil to tank to allow the fan to coast to a stop. [11] - When the right side fan reaches minimum speed, the CCU sends current out terminal H1 of CCU connector (X21) to the right side reversing fan solenoid (Y51), energizing the solenoid. This causes the right side fan to reverse direction. [12] - With the right side fan now operating in the reverse direction, the CCU de-energizes the right side fan low pressure solenoid (Y49) and ramps down the current to the right side fan speed solenoid (Y71) until the right side fan speed reaches full speed in reverse—approximately 1813 rpm—for 25 seconds. The left side fan remains in normal operating mode. [13] - After the 25 seconds has elapsed, the CCU then ramps up the current to the right side fan speed solenoid (Y71) until the fan is at minimum speed again, then energizes the right side fan low pressure solenoid (Y49). [14] - When the right fan reaches minimum speed, the CCU de-energizes the right side reversing fan solenoid (Y51). This causes the right side fan to change back to forward direction. [15] - With the right side fan operating in the forward direction, the CCU de-energizes the right side fan low pressure solenoid (Y49) and ramps down the current to the right side fan speed solenoid (Y71) to return the right side fan to normal operating mode.
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Suspension Height Control Circuit Theory of Operation
Suspension Height Control Circuit Schematic
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LEGEND: A5 A7 A8 B10 B11 B26 B43 F5 S7 X9 X10 X15 X21 X22 X23 X29 X70 X71 X72 X73 X74 Y38 Y39 Y40 Y41
Group 15: Sub-System Diagnostics
Transmission Control Unit (TCU) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Right Side Height Sensor Left Side Height Sensor Articulation Angle Sensor Output Speed Sensor Stairwell and Service Lights 10-Amp Fuse Suspension Lowering Switch Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Front Frame Harness 9-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Unswitched Power Terminal (marked as Stud 1) Transmission Control Unit (TCU) 21-Pin Connector Transmission Control Unit (TCU) 32-Pin Connector Transmission Control Harness-to-Clutch Control Harness 24-Pin Connector Clutch Control Harness-to-Retarder Control Harness 16-Pin Connector Retarder Control Harness-to-Output Speed Sensor 2-Pin Connector Right Strut Up Solenoid Right Strut Down Solenoid Left Strut Up Solenoid Left Strut Down Solenoid
The suspension height control consists of two hydraulic struts controlled by four proportional solenoid valves. The CCU controls the suspension height control system by using the following components: Left and Right Height Sensors (B10 and B11) Articulation Angle Sensor (B26) Output Speed Sensor (B43) (from TCU via the CAN) Suspension Lowering Switch (S7) Left and Right Strut Up and Strut Down Solenoids (Y38—Y41) →NOTE: The chassis control unit (CCU) (A8) uses switched power from VP1 to control the suspension strut up and strut down solenoids. For more information on the CCU and VP1 circuit, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) Right and Left Height Sensors (B10 and B11)— The height sensors are Hall-effect rotary type sensors that measure strut expansion and contraction. The CCU uses the signal from the height sensors along with information from the articulation angle sensor (B26) and the output speed sensor (B43) to determine the target strut height. Right Side Height Sensor: The CCU supplies a 5-volt reference to the sensor at pin E3 on CCU connector (X21). The CCU provides a return ground for the sensor at pin 14 on CCU connector (X22). The sensor sends an analog signal representing the strut height to pin 37 on CCU connector (X22). Left Side Height Sensor: The CCU supplies a 5-volt reference to the sensor at pin E3 on CCU connector (X21). The CCU provides a return ground for the sensor at pin 26 on CCU connector (X22). The sensor sends an analog signal representing the strut height to pin 25 on CCU connector (X22). Sensor Voltage Signal: The height sensors provide a voltage signal input to the CCU that corresponds to strut height as indicated in the following table:
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Strut Height Sensor Voltage/Strut Height Strut Height Sensor Voltage/Strut Height Signal Input
Height
Physical Description
4.37 Volts
568 mm
Minimum Strut Height
4.105 Volts
577 mm
Bottom Stopper Compressed -30 mm
3.725 Volts
605 mm
Bottom Stopper
3.38 Volts
647.4 mm
Ideal Ride Height -30 mm
3.06 Volts
662.4 mm
Ideal Ride Height -15 mm
2.74 Volts
677.4 mm
Ideal Ride Height
1.77 Volts
692.4 mm
Ideal Ride Height +15 mm
0.96 Volts
707.4 mm
Ideal Ride Height +30 mm
0.63 Volts
716.5 mm
Maximum Strut Height
Strut Height Sensor Calibration: Whenever the struts or strut height sensors have been replaced or removed and installed, calibration of the struts must be performed. →NOTE: Calibration of the strut height sensors can be performed by accessing the MAIN MENU / DIAGNOSTICS / CALIBRATION / STRUT submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Calibrations . (Group 9015-16.) Left and Right Strut Up and Strut Down Solenoids (Y38—Y41)— The CCU controls the strut up and strut down solenoids by providing pulse width modulated (PWM) signals to the solenoids. The CCU provides power to the solenoids from a high-side driver (HSD) output. It then varies the current to the solenoids by pulsing the low-side driver (LSD) output at a controlled rate. The CCU determines the target strut height by information it receives from the right and left height sensors (B10 and B11), the articulation angle sensor (B26), and the transmission output speed sensor (B43). →NOTE: For more information on the articulation angle sensor and the CCU circuits, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For more information on the output speed sensor and the TCU circuits, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) Strut Operation with Steering Straight (zero articulation angle): When the CCU detects the ride height of the machine is below the operating position (strut midpoint) as determined by the signals from the left and right side height sensors and the CCU detects machine travel speed is more than 3 km/h (2 mph) as determined by the signal from transmission control unit (TCU) (A5) via the CAN data line, the CCU will energize the right and left strut up solenoids until the operating height (strut midpoint) is obtained. (Refer to the Strut Height Sensor Voltage/Strut Height table previously in this theory.) Strut solenoid activation is as follows: The CCU provides a PWM signal from pins 12 (LSD) and 53 (HSD) on CCU connector (X22) to the right strut up solenoid (Y38). The CCU provides a PWM signal from pins 48 (LSD) and 17 (HSD) on CCU connector (X22) to the left strut up solenoid (Y40). Strut Operation with Machine Articulated Right: When the CCU detects the machine is articulated to the right, the CCU uses the signal from the articulation angle sensor to determine how much compensation is required between the left and right struts, then energizes the left and right strut solenoids until the targeted strut heights are obtained as follows: The CCU provides a PWM signal from pins 48 (LSD) and 17 (HSD) on CCU connector (X22) to the left strut up solenoid (Y40). The CCU provides a PWM signal from pins 13 (LSD) and 53 (HSD) on CCU connector (X22) to the right strut down solenoid (Y39). Strut Operation with Machine Articulated Left: When the CCU detects the machine is articulated to the left, the CCU uses the signal from the articulation angle sensor to determine how much compensation is required between the left and right struts, then energizes the left and right strut solenoids until the targeted strut heights are obtained as follows: <- Go to Section TOC
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The CCU provides a PWM signal from pins 12 (LSD) and 53 (HSD) on CCU connector (X22) to the right strut up solenoid (Y38). The CCU provides a PWM signal from pins 11 (LSD) and 17 (HSD) on CCU connector (X22) to the left strut down solenoid (Y41). If a diagnostic trouble code (DTC) occurs with the articulation angle sensor, the system will operate as if the articulation angle is 0. →NOTE: The status of the left and right strut up and strut down solenoid outputs can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) For hydraulic operation of the suspension control, see Suspension System Operation . (Group 9020-05.) Suspension Lowering Switch (S7)— The suspension lowering switch is used to lower the front of the machine by reducing the strut height. This feature is used when transporting the machine or for servicing the machine. Pushing the momentary suspension lowering switch allows unswitched current to flow from fuse (F5) to pin 31 on CCU connector (X23). When the CCU detects system voltage at pin 31, the CCU will energize the left and right strut down solenoids as follows: The CCU provides a PWM signal from pins 13 (LSD) and 53 (HSD) on CCU connector (X22) to the right strut down solenoid (Y39). The CCU provides a PWM signal from pins 11 (LSD) and 17 (HSD) on CCU connector (X22) to the left strut down solenoid (Y41). With the left and right strut down solenoids energized, trapped oil in the struts is allowed to flow to tank. The struts contract, lowering the front of the machine.
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Group 15: Sub-System Diagnostics
Park Brake Circuit Theory of Operation
Park Brake Circuit Schematic LEGEND: A2 A7 A8 B15 B24 F4 W34 X3 X9 <- Go to Section TOC
25-Button Sealed Switch Module (SSM) (OC3) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Park Brake Pressure Switch Service Brake Light Switch Brake Light Switch 10-Amp Fuse Hydraulic Harness Ground Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Section 9015 page 238
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X21 X22 X23 X29 Y45 Y46
Group 15: Sub-System Diagnostics
Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Unswitched Power Terminal Park Brake Release Solenoid 2 Park Brake Release Solenoid 1
→NOTE: The park brake is spring applied, hydraulically released. Park Brake Pressure Switch (B15)— The normally open park brake pressure switch is open when no hydraulic pressure is present at the park brake actuator (park brake engaged). When the park brake pressure switch is open, no ground signal is present at pin 24 on connector (X23) of the chassis control unit (CCU) (A8). When the CCU does not detect a ground signal at pin 24 of connector (X23), the CCU sends a message across the CAN data line to the CAN monitor unit (CMU) (A7), causing the park brake indicator on the CMU to come on. The status of the park brake pressure switch can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) When hydraulic pressure is present at the park brake actuator (park brake disengaged), the park brake pressure switch closes, connecting pin 24 on CCU connector (X23) to the hydraulic harness ground (W34). When the CCU detects ground at pin 24, the CCU sends a message across the CAN data line to the CAN monitor unit (CMU) (A7), causing the park brake indicator on the CMU to turn off. For more information on the CCU circuit, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For more information on the CAN circuits, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) For more information on the CMU, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) Park Brake Release— To release the park brake, the CCU must detect the following: Ignition power ON. CAN message from 25-button SSM, requesting park brake release. Input from service brake light switch (B24). Engine speed greater than 300 rpm. Travel speed less than 1 km/h (0.6 mph). Momentarily pushing the park brake switch on the 25-button sealed switch module (SSM) (OC3) (A2) causes the SSM to send a message across the controller area network (CAN) 1 data line to the CCU, requesting the park brake be released. When the CCU receives this CAN message, the CCU checks the signal from the service brake light switch (B24) at pin 23 of CCU connector (X23) to verify that the service brakes are applied. For more information on the service brake light switch. see Service Brake Light and Brake Accumulator Low Pressure Circuits Theory of Operation . (Group 9015-15.) →NOTE: If the service brake pedal is not pushed when the park brake switch on the 25-button SSM is pushed, a pop-up message will appear on the CMU display, informing the operator to apply the service brakes. The CCU also monitors signals from the CAN 1 data line, concerning status of engine rpm, engine cranking, ignition power status, and travel speed. →NOTE: The CCU uses power from VP1 input to provide power to the park brake release solenoids. For more information on the VP1 input and CCU outputs, see Chassis Control Unit (CCU) Outputs . (Group 9015-20.) When the CCU is satisfied that all conditions are met, the CCU will send current from pin 45 on CCU connector (X22) to the park brake release solenoid 1 (Y46), energizing the solenoid. The CCU waits 0.5 second before sending current from pin 46 on CCU connector (X22) to the park brake release solenoid 2 (Y45), energizing this solenoid. With both park brake release solenoids energized, hydraulic pressure is allowed to flow to the park brake actuator, releasing the park brake. For information on the hydraulic control of the park brake, see Park Brake Operation . (Group 9020-05.)
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Group 15: Sub-System Diagnostics
→NOTE: Malfunctioning of park brake pressure switch will allow the park brake to release but prevent the machine to shift in gear. During this, the park brake indicator on the monitor will remain illuminated. The output status of both park brake release solenoids can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Park Brake Engaged— The park brake will engage if any of the following conditions occur: CAN message from 25-button SSM requesting park brake engagement when ground speed is less than 1 km/h (0.6 mph). →NOTE: If the transmission output shaft speed is greater than 375 rpm when the CCU receives the request from the 25-button SSM to engage the park brake, the CCU will initiate a controlled stop. For information on the controlled shutdown, see Stopping Engine . (Operator’s Manual.) Loss of ignition power. Engine cranking. Engine speed drops to less than 50 rpm. If any of these events occur, the CCU will de-energize park brake release solenoid 2 (Y45). After 0.1 second, the CCU will then de-energize park brake release solenoid 1 (Y46). With both park brake release solenoids de-energized, hydraulic oil pressure to the park brake actuator is blocked, allowing the park brake to engage. For more information on the hydraulic control of the park brake, see Park Brake Operation . (Group 9020-05.) The park brake will also engage if an uncontrolled loss of hydraulic pressure occurs to the park brake actuator.
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Group 15: Sub-System Diagnostics
Service Brake Light and Brake Accumulator Low Pressure Circuits Theory of Operation
Service Brake Light and Brake Accumulator Low Pressure Circuits Schematic LEGEND: A5 A7
Transmission Control Unit (TCU) CAN Monitor Unit (CMU)
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A8 B24 B35 E10 E11 F4 F30 H22 W34 X2 X3 X8 X9 X10 X17 X21 X23 X29 X70
Group 15: Sub-System Diagnostics
Chassis Control Unit (CCU) Service Brake Light Switch Brake Accumulator Low Pressure Switch Right Rear Brake/Tail Light Left Rear Brake/Tail Light Brake Light Switch 10-Amp Fuse Seat Compressor and Brake Accumulator Low Pressure Sensor 10-Amp Fuse Buzzer Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Rear Frame Harness-to-Rear Lights Harness 8-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Unswitched Power Terminal Transmission Control Unit (TCU) 21-Pin Connector
→NOTE: The CCU uses power from VP3 input to provide power to the service brake lights. For more information on the VP3 input and CCU outputs, see Chassis Control Unit (CCU) Outputs . (Group 9015-20.) →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) Service Brake Light Switch (B24)— Unswitched power from fuse (F4) is available at the service brake light switch. When the service brakes are applied, the contacts of the service brake light switch close, allowing current to flow to chassis control unit (CCU) (A8) at pin 23 on connector (X23). →NOTE: The status of the brake light switch can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. The input is labeled BRAKE SWITCH 1. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) When the CCU detects current at pin 23 on connector (X23), the CCU sends current from pin 6 on CCU connector (X23) to pin 3 on left rear brake/tail light (E11) and right rear brake/tail light (E10), causing the brake lights to come on. The brake light circuit will function when the ignition is ON or OFF. →NOTE: The status of the brake light output can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) The CCU also sends a signal across the controller area network (CAN) to the transmission control unit (TCU) (A5), causing the TCU to activate the retarder system. For more information on the retarder system, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) For information on the CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) The retarder will activate the brake lights even if the service brakes are not applied. When the retarder is active, the TCU sends a signal to the CCU across the CAN data line. When the CCU receives this signal, it sends current from pin 6 on CCU connector (X23) to the left and right brake lights, causing the brake lights to come on. Brake Accumulator Low Pressure Switch (B35)— The brake accumulator low pressure switch is a normally open switch. When the brake accumulator charge pressure is above the minimum specification, the pressure switch is closed, allowing current to flow from fuse (F30) to pin 26 on CCU connector (X23). If the service brake accumulator charge pressure drops below the minimum set point, the pressure switch opens. If the CCU does not detect a signal at pin 26 on CCU connector (X23) for more than 3 seconds when the engine is running, the CCU will generate a diagnostic trouble code (DTC) and transmit a low brake accumulator pressure message across the CAN data line to <- Go to Section TOC
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the CAN monitor unit (CMU) (A7). When the CMU receives the CAN message, it will activate the buzzer (H22) and cause the STOP indicator and check service brake indicator to come on. If a low brake accumulator pressure DTC is active and the CCU detects a signal at pin 26 on CCU connector (X23) for more than 3 seconds, the CCU will clear the DTC and transmit a message across the CAN data line to the CAN monitor unit (CMU) (A7), deactivating the buzzer, STOP indicator, and check service brake indicator. →NOTE: The status of the brake accumulator low pressure switch can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.)
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Group 15: Sub-System Diagnostics
Headlights and Tail Lights Circuits Theory of Operation
Headlights and Tail Lights Circuits Schematic
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LEGEND: A1 A7 A8 E4 E5 E7 E8 E10 E11 E12 F17 S2 W33 W34 X2 X3 X8 X14 X17 X21 X22 X23 X30
Group 15: Sub-System Diagnostics
15-Button Sealed Switch Module (SSM) (OC4) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Right Low Beam Headlight Right High Beam Headlight Left Low Beam Headlight Left High Beam Headlight Right Rear Brake/Tail Light Left Rear Brake/Tail Light License Plate Light (if equipped) Headlights, Tail Lights, and Turn Lights 15-Amp Fuse Steering Column Switch Front Frame Harness Ground Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Front Frame Harness 21-Pin Connector Rear Frame Harness-to-Rear Lights Harness 8-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Switched Power Terminal
Headlights and Tail Lights Operation— The headlights and tail lights are controlled by the 15-button sealed switch module (SSM) (OC4) (A1) and chassis control unit (CCU) (A8). Further control of the headlights is provided by the steering column switch (S2), which is used to switch between low beams, high beams, and momentary high beams (DIPS). The CAN monitor unit (CMU) (A7) provides a high beam indicator to inform the operator when the high beam headlights are on. The 15-button SSM, CMU, and CCU communicate data across the controller area network (CAN). →NOTE: For more information on the CAN circuits, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) For more information on the CCU circuit, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For more information on the SSM and CMU, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) When ignition power is ON and the headlight switch on the 15-button SSM is pushed, the SSM transmits the switch status across the CAN data line to the CCU. When the CCU determines that the input is valid, the CCU transmits a message back to the SSM, causing the switch LED to come on. The switch LED (when lit) indicates the CCU has enabled the headlight and park light circuit. →NOTE: The on/off state of the headlight and park lights is stored in the CCU memory at power-down. →NOTE: The CCU uses power from VP1 input to provide power to the headlights and tail lights circuits. For more information on the VP1 input and CCU outputs, see Chassis Control Unit (CCU) Outputs . (Group 9015-20.) Headlights— The headlights are controlled by the steering column switch (S2). Low Beams: When the steering column switch lever is in the detented (middle) position 0, the steering column switch directs system voltage from fuse (F17) to the CCU as follows: Voltage at pin 36 on CCU connector (X23). No voltage at pin 13 on CCU connector (X23).
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Group 15: Sub-System Diagnostics
→NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) →NOTE: The status of the steering column switch low beams input can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) When the CCU receives the message from the 15-button SSM to enable headlights and detects system voltage at pin 36 and no voltage at pin 13, the CCU will send current from pin 6 on CCU connector (X22) to pin 1 on the right and left low beam headlights (E4 and E7), causing the low beams to come on. →NOTE: The status of the low beams output can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) High Beams: When the steering column switch lever is in the detented position 1 or the momentary position 2, the steering column switch directs system voltage from fuse (F17) to the CCU as follows: Voltage at pin 13 on CCU connector (X23). No voltage at pin 36 on CCU connector (X23). The status of the steering column switch high beams input can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) When the CCU receives the message from the 15-button SSM to enable headlights and detects system voltage at pin 13 and no voltage at pin 36, the CCU will send current out pin 3 on CCU connector (X22) to pin 1 on the right and left high beam headlights (E5 and E8), causing the high beams to come on. →NOTE: The status of the high beams output can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) With the high beams enabled, the CCU sends a signal to the CMU via the CAN data line, causing the high beam indicator to come on. Ground for the headlights is provided by front frame harness ground (W33). Tail Lights— When the CCU receives the message from the 15-button SSM to enable the headlights, the CCU sends current out pin 5 on CCU connector (X22) to pin 2 on the right rear brake/tail light (E10) and left rear brake/tail light (E11), causing the left and right tail lights to come on. →NOTE: The status of the tail lights output can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. The output is labeled PARK LIGHTS. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Current also flows to the license plate light (E12) (if equipped), causing this light to come on. Ground for the tail lights and license plate light is provided by front frame harness ground (W33). →NOTE: The license plate light is an option that must be enabled in the monitor menus for it to function. If equipped, the feature is enabled and disabled by accessing the MAIN MENU / SETUP / OPTIONS / LIGHTING OPTIONS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Machine Options . (Group 9015-16.)
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Group 15: Sub-System Diagnostics
Turn Lights and Four-Way Hazard Lights Circuits Theory of Operation
Turn Lights and Four-Way Hazard Lights Circuits Schematic
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LEGEND: A2 A7 A8 E1 E2 E3 E6 F17 S2 W33 W34 X2 X3 X8 X14 X17 X21 X23 X30
Group 15: Sub-System Diagnostics
25-Button Sealed Switch Module (SSM) (OC3) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Right Rear Turn Light Left Rear Turn Light Right Front Turn Light Left Front Turn Light Headlights, Tail Lights, and Turn Lights 15-Amp Fuse Steering Column Switch Front Frame Harness Ground Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Front Frame Harness 21-Pin Connector Rear Frame Harness-to-Rear Lights Harness 8-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Switched Power Terminal
Turn Lights— The turn lights are controlled by the steering column switch (S2) and chassis control unit (CCU) (A8). →NOTE: The CCU uses power from VP3 input to provide power to the turn lights circuits. For more information on the VP3 input and CCU outputs, see Chassis Control Unit (CCU) Outputs . (Group 9015-20.) →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) Left Turn: When ignition power is ON and the lever of the steering column switch is moved to the left-turn position, the steering column switch directs system voltage from fuse (F17) to pin 37 on CCU connector (X23). →NOTE: The status of the left turn input signal can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) When the CCU detects system voltage at pin 37 on CCU connector (X23), it sends pulsing current with a 50% duty cycle at 1second intervals from pin 18 on CCU connector (X23) to the left rear turn light (E2) and left front turn light (E6), causing the left turn lights to flash. →NOTE: The status of the left turn lights output can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) The CCU also sends a signal across the CAN data line to the CAN monitor unit (CMU) (A7), causing the left turn indicator arrow on the CMU to flash. →NOTE: For more information on the CAN circuits, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) For more information on the CCU circuit, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For more information on the CMU, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) Right Turn: When ignition power is ON and the lever of the steering column switch is moved to the right-turn position, the <- Go to Section TOC
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steering column switch directs system voltage from fuse (F17) to pin 25 on CCU connector (X23). →NOTE: The status of the right turn input signal can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) When the CCU detects system voltage at pin 25 on CCU connector (X23), it sends pulsing current with a 50% duty cycle at 1second intervals from pin 42 on CCU connector (X23) to the right rear turn light (E1) and right front turn light (E3), causing the right turn lights to flash. →NOTE: The status of the right turn lights output can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) The CCU also sends a signal across the CAN data line to the CAN monitor unit (CMU) (A7), causing the right turn indicator arrow on the CMU to flash. Four-Way Hazard Lights— When ignition power is ON and the four-way flasher switch on the 25-button sealed switch module (SSM) (OC3) (A2) is pushed, the SSM sends a signal across the CAN data line to the CCU, requesting four-way hazard lights. When the CCU determines that the input is valid, the CCU sends a signal back across the CAN data line to the 25-button SSM, causing the LED on the four-way flasher switch to come on. The CCU then sends pulsing current with a 50% duty cycle at 1-second intervals to the turn lights (E1, E2, E3, and E6), causing all four lights to flash at the same time. →NOTE: The status of the four-way hazard lights input signal can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) The CCU also sends a signal across the CAN data line to the CMU, causing both the left and right turn indicator arrows on the CMU to flash at the same rate as the turn lights. Four-Way Hazard and Turn Lights Activated at Same Time: If the left turn signal is selected when the four-way hazard lights are active, the CCU sends current to the turn lights as follows: Pulsing current to left turn lights (E2 and E6). Continuous current to right turn lights (E1 and E3). If the right turn signal is selected when the four-way hazard lights are active, the CCU sends current to the turn lights as follows: Pulsing current to right turn lights (E1 and E3). Continuous current to left turn lights (E2 and E6). CCU Wake-Up: The four-way hazard lights can be activated when the ignition power is OFF. Pushing the four-way flasher switch on the 25-button SSM when the ignition is OFF causes the SSM to send a wake-up signal to pin 19 on CCU connector (X23). When the CCU detects this signal, it sends pulsing current to all front and rear turn lights.
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Work Lights and Rotating Beacon Circuits Theory of Operation
Work Lights and Rotating Beacon Circuits Schematic LEGEND: A1 A8 E28 E29 H21 W31 X21 X22 X44 <- Go to Section TOC
15-Button Sealed Switch Module (SSM) (OC4) Chassis Control Unit (CCU) Left Work Light Right Work Light Rotating Beacon Cab Ground Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Cab Harness-to-Work Light Harness 3-Pin Connector Section 9015 page 250
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→NOTE: The work lights and rotating beacon are options that must be enabled in the monitor menus for them to function. These features can be enabled or disabled by accessing the MAIN MENU / SETUP / OPTIONS / LIGHTING OPTIONS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Machine Options . (Group 9015-16.) →NOTE: The CCU uses power from VP1 input to provide power to the work lights and rotating beacon. For more information on the VP1 input and CCU outputs, see Chassis Control Unit (CCU) Outputs . (Group 9015-20.) The work lights and rotating beacon are controlled by the 15-button sealed switch module (SSM) (OC4) (A1) and the chassis control unit (CCU) (A8). The 15-button SSM and CCU communicate data across the controller area network (CAN). →NOTE: For more information on the CAN circuits, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) For more information on the CCU circuit, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For more information on the 15-button SSM, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) Work Lights— When ignition power is ON and the front work light switch on the 15-button SSM is pushed, the SSM transmits the switch status across the CAN data line to the CCU. When the CCU determines that the input is valid, the CCU transmits a message back to the SSM, causing the switch LED to come on, indicating that the work light circuit is activated. At the same time, the CCU sends current from pin 18 on CCU connector (X22) to the left and right work lights (E28 and E29), activating the lights. Ground for the work lights is provided by cab ground (W31). The status of the work lights output can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Rotating Beacon— When ignition power is ON and the rotating beacon light switch on the 15-button SSM is pushed, the SSM transmits the switch status across the CAN data line to the CCU. When the CCU determines that the input is valid, the CCU transmits a message back to the SSM, causing the switch LED to come on, indicating that the beacon circuit is activated. At the same time, the CCU sends current from pin L4 on CCU connector (X21) to the rotating beacon (H21), activating the beacon. Ground for the rotating beacon is provided by cab ground (W31). The status of the rotating beacon output can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.)
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Stairwell and Service Lights Circuits Theory of Operation
Stairwell and Service Lights Circuits Schematic
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LEGEND: A1 A7 A8 E14 E19 E21 F5 S4 S6 W31 W33 X10 X14 X15 X21 X22 X23 X29 X45
Group 15: Sub-System Diagnostics
15-Button Sealed Switch Module (SSM) (OC4) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Right Stairwell Light (if equipped) Left Stairwell Light Service Light Stairwell and Service Lights 10-Amp Fuse Remote Stairwell Light Switch Service Light Switch Cab Ground Front Frame Harness Ground Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Front Frame Harness 21-Pin Connector Cab Harness-to-Front Frame Harness 9-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Unswitched Power Terminal Cab Harness-to-Rear Work Light Harness 4-Pin Connector
→NOTE: The CCU uses power from VP3 input to provide power to the service and stairwell lights. For more information on the VP3 input and CCU outputs, see Chassis Control Unit (CCU) Outputs . (Group 9015-20.) →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.)
Service Light Circuit The service light circuit consists of the service light switch (S6) and service light (E21). The service light circuit will function when the ignition is ON or OFF. Service Light Switch: The service light switch is a normally open magnetic switch that closes when it detects metal. When the front service door opens, a metal tab on the door moves near the magnetic switch, causing the switch to close. When the front service door closes, the metal tab moves away from the magnetic switch, causing the switch to open. When the switch is closed, current from fuse (F5) flows to pin 40 on the chassis control unit (CCU) connector (X22). →NOTE: The status of the service light switch can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) If the CCU detects the input at pin 40 on CCU connector (X22) when the transmission is shifted into forward or reverse gear, the CCU will send a message across the CAN data line to the CMU, causing a pop-up screen to appear on the CMU display that informs the operator that the front service door is open. Service Light: Whenever the CCU detects an input at pin 40 on CCU connector (X22) (front service door open, switch closed), the CCU sends current from pin 1 of CCU connector (X23) to the service light, causing the light to come on. The CCU will activate the service light even if ignition power is OFF. →NOTE: The status of the service light output can be viewed as a live value by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUT LIGHTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Ground for the service light is provided by front frame harness ground (W33). Anytime the CCU detects a transition of the service light switch from open to closed, the service light timer inside the CCU will reset. If the service door is open for 5, 10, 15, or 20 minutes (depending on timer setting in the CMU menus), the service light will automatically turn off. <- Go to Section TOC
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→NOTE: Setting of the service light timer can be adjusted by accessing the MAIN MENU / SETUP / SERVICE LIGHT TIMER submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Setup—Service Light Timer . (Operator’s Manual.)
Stairwell Light Circuit The stairwell light circuit consists of the following: Stairwell light switch on 15-button SSM (A1). Remote stairwell light switch (S4). Right stairwell light (E14) (if equipped). Left stairwell light (E19). Remote Stairwell Light Switch: The remote stairwell light switch is a normally open momentary switch. Pushing the switch causes the switch to close, allowing current to flow from fuse (F5) to pin 52 on CCU connector (X22). If ignition power is OFF, the input at pin 52 will cause the CCU to turn on the stairwell light even when ignition power is OFF. →NOTE: The status of the remote stairwell light switch can be viewed as a live value by accessing MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Stairwell Light Switch on SSM: When ignition power is ON and the stairwell light switch on 15-button SSM is pushed, the SSM transmits the switch status across the CAN data line to the CCU. When the CCU determines that the input is valid, the CCU transmits a message back to the SSM. This causes the switch LED to come on, indicating the CCU has enabled the stairwell light output. Stairwell Light: Whenever the CCU receives the stairwell light message from the 15-button SSM or detects an input at pin 52 on CCU connector (X22) from the remote stairwell light switch, the CCU will send current from pin 30 of CCU connector (X23) to the left stairwell light (E19), causing the light to come on. Current will also flow to the right stairwell light (E14) (if equipped), causing this light to come on. Pushing either stairwell light switch on the 15-button SSM or the remote stairwell light switch again will turn off the stairwell light. →NOTE: The status of the stairwell light output can be viewed as a live value by accessing MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUT LIGHTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Ground for the stairwell light is provided by cab ground (W31). Anytime the CCU receives the stairwell light message from the 15-button SSM or detects an input at pin 52 on CCU connector (X22) from the remote stairwell light switch, a stairwell light timer inside the CCU will reset. If the stairwell light is on for 1, 2, 3, 4, or 5 minutes (depending on timer setting in the CMU menus), the stairwell light will automatically turn off. →NOTE: Setting of the stairwell light timer can be adjusted by accessing the MAIN MENU / SETUP / STAIR LIGHT TIMER submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Setup—Stairwell Light Timer . (Operator’s Manual.)
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Backup Alarm and Backup Lights Circuits Theory of Operation
Backup Alarm and Backup Lights Circuit Schematic LEGEND: A1 A2 A5 A8
15-Button Sealed Switch Module (SSM) (OC4) 25-Button Sealed Switch Module (SSM) (OC3) Transmission Control Unit (TCU) Chassis Control Unit (CCU)
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E15 E16 E17 E18 H1 W31 W34 X2 X3 X8 X9 X21 X22 X45
Group 15: Sub-System Diagnostics
Right Backup Light Left Backup Light Left Articulation Backup Light Right Articulation Backup Light Backup Alarm Cab Ground Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Cab Harness-to-Rear Work Light Harness 4-Pin Connector
Backup Lights and Backup Alarm →NOTE: The CCU uses power from VP1 input to provide power to the backup lights circuit. For more information on the VP1 input and CCU outputs, see Chassis Control Unit (CCU) Outputs . (Group 9015-20.) The backup lights and backup alarm are controlled by the 25-button sealed switch module (SSM) (OC3) (A2), chassis control unit (CCU) (A8), and transmission control unit (TCU) (A5). The 25-button SSM, CCU, and TCU communicate data across the controller area network (CAN) data line. →NOTE: For information on the CAN circuits, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) For information on the CCU circuit, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For information on the 25-button SSM, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) For information on the TCU, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) When reverse gear (R) is selected, the TCU sends a signal to the CCU across the CAN data line, informing the CCU that the transmission is in reverse gear. When the CCU receives this signal, it sends current from pin 1 on connector (X22) to the right and left backup lights (E15 and E16), causing the lights to come on. Current from pin 1 also flows to backup alarm (H1), activating the alarm. The hydraulic harness ground (W34) provides ground to the backup lights and backup alarm. →NOTE: The status of the backup lights output can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.)
Articulation Backup Lights (If Equipped) The articulation backup lights have four modes of operation that are selected using the 15-button sealed switch module (SSM) (OC4) (A1). For description and operation of the four modes, see Sealed Switch Module (SSM) . (Operator’s Manual.) →NOTE: The articulation backup lights are an option that must be enabled in the monitor menus for it to function. This feature can be enabled or disabled by accessing the MAIN MENU / SETUP / OPTIONS / LIGHTING OPTIONS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Machine Options . (Group 9015-16.) When the articulation backup light switch is pushed on the 15-button SSM, the SSM transmits the switch status across the CAN <- Go to Section TOC
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data line to the CCU. When the CCU determines the switch status, the CCU transmits a signal back to the SSM, causing the appropriate switch LED or LEDs to come on. The switch LEDs (when lit) indicate the CCU has enabled the mode selected. When the CCU determines that the conditions have been met for the mode selected, the CCU will send current from pin L4 on connector (X21) to the left and right articulation backup lights (E17 and E18), causing the lights to come on. Ground for the articulation backup lights is provided by cab ground (W31). →NOTE: The status of the articulation backup lights output can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.)
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Horn Circuit Theory of Operation
Horn Circuit Schematic LEGEND: A8 B3 F3 S2 W33 X14 X22 X23 X29 <- Go to Section TOC
Chassis Control Unit (CCU) Electric Horn Horn 10-Amp Fuse Steering Column Switch Front Frame Harness Ground Cab Harness-to-Front Frame Harness 21-Pin Connector Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Unswitched Power Terminal Section 9015 page 258
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→NOTE: The chassis control unit (CCU) (A8) uses power from VP3 input to provide power to the horn. For more information on the VP3 input and CCU outputs: See Chassis Control Unit (CCU) Outputs . (Group 9015-20.) See Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) Unswitched power from fuse (F3) is available to the horn switch at pin 12 of the steering column switch (S2). Pushing the horn switch causes current to flow to the chassis control unit (CCU) (A8) at pin 28 of connector (X22). →NOTE: The status of the horn switch can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) When the CCU detects current at pin 28, the CCU sends current from pin 3 on CCU connector (X23) to the electric horn (B3), activating the horn. The horn activates when ignition power is ON or OFF. →NOTE: The status of the horn output can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) The following features can be enabled to provide automatic horn activation: Auto horn at engine start. Full load horn alert. Body up alert. Inter-axle differential lock (IDL) alert. →NOTE: These features can be enabled or disabled by accessing the MAIN MENU / SETUP / OPTIONS / ALERT OPTIONS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Machine Options . (Group 9015-16.)
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Rear View Camera Circuit Theory of Operation
Rear View Camera Circuit Schematic LEGEND: A9 A10 F26 W31 X30 X67
Rear View Monitor Rear View Camera Auto Greasing and Rear View Monitor 5-Amp Fuse Cab Ground Fuse Block Switched Power Terminal Rear View Camera Articulation 4-Pin Connector
The rear view camera is a self-contained system that requires only power and ground from the machine’s electrical system. <- Go to Section TOC
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→NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) When ignition power is ON, current flows through fuse (F26) to the rear view monitor (A9), powering up the monitor. Ground is provided to the rear view monitor from cab ground (W31). When the rear view monitor powers up, the monitor provides 12 volts to the rear view camera (A10) at pins 3 and 4 of the 4-pin connector. The rear view camera then sends a video signal back to the rear view monitor at pins 1 and 2 of the 4-pin connector. For operation of the rear view camera, see Rear View Monitor—If Equipped . (Operator’s Manual.)
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Windshield Wipers and Washers Circuits Theory of Operation
Windshield Wipers and Washers Circuits Schematic LEGEND: A2 A8 F18 M3 <- Go to Section TOC
25-Button Sealed Switch Module (SSM) (OC3) Chassis Control Unit (CCU) Wiper Motor 10-Amp Fuse Front Windshield Wiper Motor Section 9015 page 262
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M5 W31 W33 X14 X21 X22 X23 X30
Group 15: Sub-System Diagnostics
Front Windshield Washer Pump Motor Cab Ground Front Frame Harness Ground Cab Harness-to-Front Frame Harness 21-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Switched Power Terminal
→NOTE: The chassis control unit (CCU) (A8) uses power from VP1 input to provide power to the low speed wiper, high speed wiper, and washer pump outputs. For more information on the VP1 input and CCU outputs, see Chassis Control Unit (CCU) Outputs . (Group 9015-20.) →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) The windshield wiper and washer circuits are controlled by the chassis control unit (CCU) (A8) and the 25-button sealed switch module (SSM) (OC3) (A2). The CCU and SSM communicate with each other using the controller area network (CAN). For information on the CCU circuit, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For information on the CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) Windshield Wiper Switch on 25-Button SSM— When the front windshield wiper switch is pushed on the 25-button SSM, the SSM transmits the switch status across the CAN data line to the CCU. When the CCU determines that the input is valid, the CCU transmits a message back to the SSM. This causes the appropriate switch LED to come on, indicating the CCU has activated the corresponding wiper circuit. The front windshield wiper switch activates the following wiper modes as indicated by LEDs on the switch. Each time the switch is pushed and released, it sequences to the next mode. Intermittent (left LED on) Low Speed (middle LED on) High Speed (right LED on) OFF (PARK) (all LEDs off) Front Windshield Wiper Motor (M3)— The windshield wiper motor can be activated only when ignition power is ON. The CCU remembers the wiper control mode when ignition power is turned OFF. →NOTE: The wiper motor low and high speed outputs can be monitored by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu of the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) The wiper motor has internal thermal protection to prevent damage from overheating during wiper stall. Low Speed Mode: When in this mode, the CCU sends current out pin 4 on CCU connector (X22) to pin 4 on the front windshield wiper motor (M3), operating the motor continuously at slow speed. The CCU ignores the PARK signal when in this mode. High Speed Mode: When in this mode, the CCU sends current out pin 30 on CCU connector (X22) to pin 2 on the front windshield wiper motor to operate the wiper motor continuously at high speed. The CCU ignores the PARK signal when in this mode. Intermittent Mode: When in this mode, the CCU sends current out pin 4 on CCU connector (X22) to activate the front windshield wiper motor in low speed. The CCU provides current to the wiper motor for one complete cycle until the CCU detects the signal indicating the wiper is in the PARK position. For information on PARK position, see OFF (PARK) Mode later in this theory of operation. When the CCU detects the wiper is in the PARK position, the CCU stops current flow out pin 4. The CCU then waits for 3, 5, 8, or 10 seconds, depending on the delay setting, before sending current out pin 4 again to repeat the intermittent cycle. Intermittent wiper operation will continue until another mode is selected on the SSM.
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→NOTE: The wiper delay setting can be changed by accessing the MAIN MENU / SETUP / WIPER DELAY TIME submenu of the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Setup—Wiper Delay Time . (Operator’s Manual.) If the CCU does not detect the PARK signal because of a broken PARK signal wire or a damaged PARK signal input, the CCU will continue to send current out pin 4, keeping the wiper motor continuously activated in low speed mode until another mode is selected. OFF (PARK) Mode: The CCU continuously monitors the signal at pin 28 on CCU connector (X23) to determine whether the wiper is at PARK position or NOT PARK position. It does this by detecting the following: Ground (indicates PARK position) System voltage (indicates NOT PARK position) →NOTE: The wiper motor PARK input can be monitored by accessing the MAIN MENUS / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu of the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) The wiper motor contains an internal switch that connects pins 1 and 6 or pins 1 and 3 on the wiper motor, depending on the position of the wiper. When the wiper is in the PARK position, a cam inside the wiper motor assembly will cause the internal switch to connect pins 1 and 6, and disconnect pins 1 and 3. With pins 1 and 6 connected, ground is available to pin 28 on CCU connector (X23). When the CCU detects ground (PARK signal) at pin 28, the CCU will stop current flow out pin 4 or 30 (depending on operating mode) on CCU connector (X22), deactivating the wiper motor. When the wiper is in a NOT PARK position, the cam inside the wiper motor assembly will cause the internal switch to connect pins 1 and 3, and disconnect pins 1 and 6. With pins 1 and 3 connected, system voltage from fuse (F18) is sent to pin 28 on CCU connector (X23). When the CCU detects system voltage at pin 28, the CCU will send current out pin 4 on CCU connector (X22), activating the wiper motor in low speed. The CCU provides current to the wiper motor until the wiper reaches the PARK position. →NOTE: The wiper control will not default to PARK mode if ignition is turned OFF and the wiper is in mid stroke. If the wiper is operating and OFF (PARK) mode is selected on the SSM when the wiper is NOT at the PARK position, the wiper will continue to operate until the CCU detects the PARK signal (ground at pin 28). If the CCU does not detect the PARK signal within a certain amount of time after detecting the signal from the SSM to stop the wiper, the CCU will stop the wiper at whatever position it is when the time elapses. This is to prevent the wiper from continuously operating due to a broken PARK signal wire or if the PARK signal input is damaged. Front Windshield Washer Pump Motor (M5)— When the front windshield washer switch is pushed and held for more than 0.5 second, the 25-button SSM sends a message to the CCU via the CAN data line, requesting that the CCU activate the washer pump motor. The CCU then sends current out pin G4 on CCU connector (X21) to the washer pump motor, activating the motor until the windshield washer switch is released. Ground for the washer pump motor is provided by front frame harness ground (W33). →NOTE: The washer pump motor pump output can be monitored by accessing the MAIN MENUS / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu of the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) If the front windshield wiper is not operating or if the wiper is in the intermittent mode when the windshield washer switch is pushed, the front windshield wiper motor will activate in the continuous low speed mode for three complete wipe cycles before returning to the PARK position.
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Air Conditioner and Heater Circuits Theory of Operation
Air Conditioner and Heater Circuits Schematic
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LEGEND: A1 A7 A8 A16 B27 B28 B29 B30 F20 M2 M4 M6 M7 M8 R11 V4 W33 W35 X14 X21 X22 X23 X30 X32 X33 X46 X84 X85 Y22
Group 15: Sub-System Diagnostics
15-Button Sealed Switch Module (SSM) (OC4) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Air Conditioner Control Unit Air Conditioner High/Low Pressure Switch Air Conditioner Freeze Control Switch Air Conditioner Evaporator Temperature Sensor Air Conditioner Evaporator Inlet Sensor Air Conditioner Unit (ACU) 10-Amp Fuse Heater Control Valve Actuator Blower Motor Recirculation Vent Actuator Defrost and Middle Vent Actuator Floor Vent Actuator Blower Motor Resistor/Thermofuse Air Conditioner Compressor Clutch Diode Front Frame Harness Ground Air Conditioner Ground Cab Harness-to-Front Frame Harness 21-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Switched Power Terminal Air Conditioner High/Low Pressure Switch 1-Pin Connector (A) Air Conditioner High/Low Pressure Switch 1-Pin Connector (B) Cab Harness-to-Air Conditioner Actuator Harness 12-Pin Connector Air Conditioner Actuator Control Unit 8-Pin Connector Air Conditioner Actuator Control Unit 6-Pin Connector Air Conditioner Compressor Clutch
→NOTE: The CCU uses power from VP1 input to provide power to the HVAC blower and actuators. For more information on the VP1 input and CCU outputs, see Chassis Control Unit (CCU) Outputs . (Group 9015-20.) →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) Air Conditioner and Heater System— The air conditioner and heater system is electronically controlled by the 15-button sealed switch module (SSM) (OC4) (A1), chassis control unit (CCU) (A8), and air conditioner control unit (A16). When ignition is ON, current flows from fuse (F20) to pin 6 on connector (X85), providing power to the air conditioner control unit (A16). Fuse (F20) also provides power to the air conditioner freeze control switch (B28). The 15-button SSM contains switches that allow the operator to change blower speeds, temperature settings, and air flow direction. When an SSM switch is pushed, the SSM transmits the operator’s commands to the CCU across the controller area network (CAN) data line. The CCU sends the appropriate control signals to the corresponding components to provide the desired air flow and temperature. For more information on the 15-button SSM and operating the air conditioner and heater controls, see Sealed Switch Module (SSM) . (Operator’s Manual.) Blower Motor Control— The blower speed is controlled using the blower speed increase and decrease switches on the 15button SSM. Pushing on either the increase switch or decrease switch causes a pop-up screen to display on the CAN monitor unit (CMU) (A7) for 3 seconds. The pop-up screen shows blower speed as a digital graph on the right half of the screen. For more information on operation of the blower speed switches, see Sealed Switch Module (SSM) . (Operator’s Manual.) Depending on the input received from the SSM, the CCU will activate the blower motor (M4) in low, medium, or high speed using switched power from the VP1 input. →NOTE: The blower speed outputs can be monitored by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu of the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.)
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Low Speed: When low speed is selected, the CCU sends current from pin M4 on connector (X21) to the blower motor resistor/thermofuse (R11). The current flows through two fixed resistors and a fuse, then to the blower motor. This activates the blower motor in low speed. Medium Speed: When medium speed is selected, the CCU sends current from pin L3 on connector (X21) to the blower motor resistor/thermofuse. The current flows through one fixed resistor and a fuse, then to the blower motor. This activates the motor in medium speed. High Speed: When high speed is selected, the CCU sends current from pin 4 on connector (X23) to the blower motor resistor/thermofuse. The current flows through a fuse and then to the blower motor, activating the motor in high speed. →NOTE: When the blower motor is activated in either low, medium, or high speed, one or both LEDs on the defrost/mid vent control switch will come on, depending on the vent status. If the lower vent control is enabled, the LED on this switch will also come on. When the blower motor is off, the LEDs on the defrost/mid vent control switch and the LED on the lower vent control switch will be off. The CCU remembers the state of blower speed when ignition power is turned off. Air Recirculation— When the recirculating air switch on the 15-button SSM is pushed (LED on), the CCU sends a pulse width modulated (PWM) signal having an approximate 90% duty cycle out pin 53 on CCU connector (X23) to pin 4 on the air conditioner control unit. The air conditioner control unit activates the air recirculation vent actuator (M6), which moves the air recirculation vent door to a position that prevents the outside air from entering the cab and causes inside air to recirculate inside the cab. →NOTE: The output signal to the air recirculation vent actuator can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu of the CMU menu structure. This output is labeled HVAC PWM 4 in the CMU menu. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) When the recirculating air switch is pushed again (LED off), the CCU stops sending current out pin 53 to the air conditioner unit. The recirculation vent actuator returns to the default position, allowing outside air to enter the cab. For more information on operation of the SSM switches, see Sealed Switch Module (SSM) . (Operator’s Manual.) Defrost/Mid Vent Control— Air flow to the windshield and middle vents can be controlled using the defrost/mid vent control switch on the 15-button SSM. Each time the defrost/mid vent control switch is pushed and released, the system increments to one of the following modes: Defrost (left LED on) Defrost and Middle (both LEDs on) Middle (right LED on) For operation of the SSM switches, see Sealed Switch Module (SSM) . (Operator’s Manual.) Defrost: When the defrost mode is selected, no vent actuators are activated. Air flow is directed to the windshield. Defrost and Middle: When the defrost and middle mode is selected, the CCU sends a PWM signal having an approximate 5% duty cycle out pin 41 on CCU connector (X23) to pin 3 on the air conditioner control unit. The air conditioner control unit activates the defrost and middle vent actuator (M7), which moves the defrost and middle vent door to a corresponding position that directs air flow to both the windshield and middle vents. Middle: When the middle mode is selected, the CCU sends a PWM signal with an approximate 90% duty cycle out pin 41 on CCU connector (X23) to pin 3 on the air conditioner control unit. The air conditioner control unit then activates the defrost and middle vent actuator (M7), which moves the defrost and middle vent door to a corresponding position that directs air flow to the middle vents. →NOTE: The output signal to the defrost and middle vent actuator can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu of the CMU menu structure. This output is labeled HVAC PWM 3 in the CMU menu. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Floor Vent Control— Air flow to the floor vents is controlled using the lower vent control switch on the 15-button SSM. For more information on the SSM switches, see Sealed Switch Module (SSM) . (Operator’s Manual.) When the lower vent control switch is pushed (LED on), the CCU sends a PWM signal with an approximate 90% duty cycle out <- Go to Section TOC
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pin 17 on CCU connector (X23) to pin 2 on the air conditioner control unit. The air conditioner control unit activates the floor vent actuator (M8), which moves the floor vent door to a position that directs air flow to the floor vents. →NOTE: The output signal to the flow vent actuator can be viewed as a percentage by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu of the CMU menu structure. This output is labeled HVAC PWM 2 in the CMU menu. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Air Conditioning Control— The air conditioning system will operate when the following conditions are met: Ignition power ON, engine running. Air conditioner switch on 15-button SSM is pushed (LED on). Blower speed mode is at low, medium, or high. Refrigerant pressure within specified parameters. Air conditioner high/low pressure switch (B27) is closed. Evaporator core temperature within specified parameters. Air conditioner freeze control switch (B28) is closed. When all conditions are met, the CCU sends current out pin 10 on CCU connector (X22) to the air conditioner compressor clutch (Y22), energizing the clutch. The CCU uses switched power from VP1 to activate the air conditioner compressor clutch. Air Conditioner High/Low Pressure Switch (B27): Air conditioner high/low pressure switch protects the air conditioning system when the refrigerant pressure becomes too high or too low. If either of these conditions occur, the switch contacts will open, causing the air conditioner compressor clutch to de-energize. →NOTE: The air conditioner clutch output can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUT DIGITAL submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Air Conditioner Freeze Control Switch (B28): The air conditioner freeze control switch senses the temperature in the evaporator core through a gas-filled capillary tube. The CCU monitors the air conditioner freeze control switch at pin 27 on CCU connector (X23). →NOTE: The air conditioner freeze control switch input can be monitored by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / INPUT SWITCHES submenu in the CMU menu structure. This input is labeled AC THERMO in the CMU menu. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) When the evaporator core is within normal operating parameters, the switch is closed, allowing voltage from fuse (F20) to become available at pin 27 on CCU connector (X23). When the CCU detects the voltage signal from the freeze control switch, the CCU will de-energize the air conditioner compressor clutch. When the evaporator temperature drops below specification, the switch opens, removing the voltage signal to the CCU. When the CCU does not detect the voltage signal from the freeze control switch, it will de-energize the air conditioner compressor clutch. Temperature Control— The cab temperature control has 12 settings that can be changed using the temperature increase and decrease switches on the 15-button SSM. The temperature setting increments each time the temperature increase switch is pushed. The temperature setting decrements each time the temperature decrease switch is pushed. Pushing on either the temperature increase switch or temperature decrease switch causes a pop-up screen to display on the CAN monitor unit (CMU) (A7) for 3 seconds. The pop-up screen shows temperature as a digital graph on the left half of the screen. For more information on operation of the temperature increase and decrease switches, see Sealed Switch Module (SSM) . (Operator’s Manual.) To maintain the selected cab air temperature, the CCU monitors the air conditioner evaporator inlet sensor (B30) and air conditioner evaporator temperature sensor (B29) at pins 38 and 39, respectively, on CCU connector (X23). The CCU then sends a PWM signal with the appropriate duty cycle out pin 29 on CCU connector (X23) to pin 1 on the air conditioner control unit.
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→NOTE: The output signal to the heater control actuator can be viewed by accessing the MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. This output is labeled HVAC PWM 1 in the CMU menu. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) The air conditioner control unit will then activate the heater control valve actuator (M2), causing the actuator motor to open or close the heater valve relative to the amount of current sent by the CCU. Increasing the temperature setting opens the valve. Decreasing the temperature setting closes the valve.
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Electric Mirror Circuit Theory of Operation
Electric Mirror Circuit Schematic
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LEGEND: A1 A8 F19 M9 M10 R12 R13 S3 W31 X21 X30 X36 X37
Group 15: Sub-System Diagnostics
15-Button Sealed Switch Module (SSM) (OC4) Chassis Control Unit (CCU) Mirror Switch 10-Amp Fuse Left Mirror Servo Motors Right Mirror Servo Motors Left Mirror Defrost Right Mirror Defrost Mirror Positioning Switch Cab Ground Chassis Control Unit (CCU) 48-Pin Connector (J1) Fuse Block Switched Power Terminal Cab Harness-to-Left Mirror Harness 6-Pin Connector Cab Harness-to-Right Mirror Harness 6-Pin Connector
→NOTE: The electric mirrors are an option that must be enabled in the monitor menus for it to function. The electric mirrors can be enabled or disabled by accessing the MAIN MENU / SETUP / OPTIONS / CAB OPTIONS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Machine Options . (Group 9015-16.) Mirror Positioning Circuit— Movement of the electric mirrors is controlled by the mirror positioning switch (S3). The mirror positioning switch is a multi-functional switch consisting of a mirror selector switch and a mirror direction switch. Mirror Selector Switch: The mirror selector switch enables the circuitry of the mirror to be adjusted. Moving the switch to the left detent allows the left mirror to be adjusted. Moving the switch to the right detent allows the right mirror to be adjusted. Moving the switch to the center detent disables both mirrors. Mirror Direction Switch: The mirror direction switch is a four-way switch that operates two servo motors in each mirror. One servo motor controls the mirror up-and-down movement. The other servo motor controls the mirror side-to-side movement. Power and Ground— When ignition power is ON, switched power is provided to pin 2 on the mirror positioning switch. The cab ground (W31) provides ground to pin 1 on the mirror positioning switch. →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) Mirror Up/Down and Left/Right Power and Ground Distribution Left Mirror Up/Down Positioning Left Mirror Up/Down Positioning Mirror Position Switch (S3)
Connector (X36)
Power/Ground
pin 3
pin 5
Ground
pin 5
pin 3
24V
pin 8
pin 4
Ground
Mirror Position Switch (S3)
Connector (X36)
Power/Ground
pin 3
pin 5
Ground
pin 5
pin 3
Ground
pin 8
pin 4
24V
Left Mirror Left/Right Positioning Left Mirror Left/Right Positioning
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Right Mirror Up/Down Positioning Right Mirror Up/Down Positioning Mirror Position Switch (S3)
Connector (X37)
Power/Ground
pin 3
pin 5
Ground
pin 7
pin 3
24V
pin 6
pin 4
Ground
Mirror Position Switch (S3)
Connector (X37)
Power/Ground
pin 3
pin 5
Ground
pin 7
pin 3
Ground
pin 6
pin 4
24V
Right Mirror Left/Right Positioning Right Mirror Left/Right Positioning
Left Mirror Up/Down and Left/Right Operation— The following discusses the operation of the left mirror. Operation of the right mirror is similar. Up/Down Positioning: When the mirror selector switch is at position L and the mirror direction switch is moved to the UP position, ground is supplied to the left mirror servo motors (M9) at pins 4 and 5 on connector (X36). At the same time, current flows to the up/down motor of the left mirror servo motors (M9) via pin 3 on connector (X36). This activates the up/down motor, causing the mirror lens to rotate upward. The side-to-side motor of the left mirror servo motors (M9) does not activate because ground is supplied to both sides of the motor during this time. When the mirror selector switch is at position L and the mirror direction switch is moved to the DOWN position, ground is supplied to left mirror servo motors (M9) at pin 3 on connector (X36). At the same time, power is available at pins 4 and 5 of connector (X36). The current flows through the up/down motor of the left mirror servo motors (M9), but in the opposite direction. This causes the motor to activate in reverse, which rotates the mirror lens downward. The side-to-side motor of the left mirror servo motors (M9) does not activate because power is supplied to both sides of the motor during this time. Left/Right Positioning: When the mirror selector switch is at position L and the mirror direction switch is moved to the LEFT, ground is supplied to the left mirror servo motors (M9) at pins 3 and 5 on connector (X36). At the same time, current flows to the side-to-side motor of the left mirror servo motors (M9) via pin 4 on connector (X36). This activates the side-to-side motor, causing the mirror lens to rotate to the left. The up/down motor of left mirror servo motors (M9) does not activate because ground is supplied to both sides of the motor during this time. When the mirror selector switch is at position L and the mirror direction switch is moved to the RIGHT, ground is supplied to the left mirror servo motors (M9) at pin 4 on connector (X36). At the same time, power is available at pins 3 and 5 on connector (X36). Because of this, current flows through the side-to-side motor of left mirror servo motors (M9), but in the opposite direction. This causes the motor to activate in reverse, which rotates the mirror lens to the right. The up/down motor of left mirror servo motors (M9) does not activate because power is supplied to both sides of the motor during this time. Mirror Defrost Circuit— The electric mirrors contain a heating element that is attached to the mirror’s reflective lens for defrosting and defogging purposes. The mirror defrost function is selected by pushing the heated mirror switch on the 15button sealed switch module (SSM) (OC4) (A1). When the heated mirror switch is pushed, the 15-button SSM sends a signal to the chassis control unit (CCU) (A8) across the CAN data line. When the CCU receives this signal, it sends current from pin M3 of connector (X21) to the left mirror defrost and right mirror defrost (R12 and R13), activating the heating elements. The CCU will activate the heating elements until the heated mirror switch on the SSM is pushed again or until 15 minutes have elapsed, whichever comes first. If the CCU detects cranking of the engine, the CCU will stop or prevent activation of the mirror heating elements. →NOTE: The CCU uses power from VP1 input to provide power to the heated mirror output. For more information on the VP1 input and CCU outputs, see Chassis Control Unit (CCU) Outputs . (Group 9015-20.) For more information on the CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) For more information on the CCU circuit, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For more information on the 15-button SSM, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.)
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Heated Seat and Air Seat Compressor Circuits Theory of Operation
Heated Seat and Air Seat Compressor Circuits Schematic LEGEND: A1 A8 F30 M11
15-Button Sealed Switch Module (SSM) (OC4) Chassis Control Unit (CCU) Seat Compressor and Brake Accumulator Low Pressure Sensor 10-Amp Fuse Air Seat Compressor
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R14 R15 W31 X21 X23 X29 X65 X66
Group 15: Sub-System Diagnostics
Seat Cushion Heater Back Cushion Heater Cab Ground Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J3) Fuse Block Unswitched Power Terminal Seat Heater 2-Pin Connector Seat Compressor 2-Pin Connector
→NOTE: The heated seat is an option that must be enabled in the monitor menus for it to function. The heated seat can be enabled or disabled by accessing the MAIN MENU / SETUP / OPTIONS / CAB OPTIONS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Machine Options . (Group 9015-16.) →NOTE: The CCU uses power from VP1 input to provide power to the heated seat. For more information on the VP1 input and CCU outputs, see Chassis Control Unit (CCU) Outputs . (Group 9015-20.) Heated Seat— When ignition power is ON and the heated seat switch on the 15-button sealed switch module (SSM) (A1) is pushed (LED on), the SSM sends a message across the controller area network (CAN) data line to the chassis control unit (CCU) (A8) to activate the seat heaters. When the CCU receives the message from the SSM, it sends current from pin 5 on CCU connector (X23) to the seat cushion heater (R14) and back cushion heater (R15), activating the heaters. →NOTE: The status of the seat heater output can be viewed as a live value by accessing MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) For more information on the SSM, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) For more information on the CCU circuit, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For information on the CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) Air Seat Compressor— Unswitched power from fuse (F30) is available to pin A on air seat compressor (M11). The cab ground (W31) provides ground to pin B on the air seat compressor. →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) Pushing the momentary air seat compressor switch activates the air seat compressor motor, which provides compressed air to the air seat suspension.
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Tire Pressure Monitoring (TPM) System Theory of Operation
Tire Pressure Monitoring (TPM) System Circuit Schematic
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LEGEND: A7 CAN Monitor Unit (CMU) A8 Chassis Control Unit (CCU) A19 Tire Pressure Monitoring (TPM) System Controller B48 Tire Pressure Monitoring (TPM) System Sensor (right front) B49 Tire Pressure Monitoring (TPM) System Sensor (right middle) B50 Tire Pressure Monitoring (TPM) System Sensor (right rear) B51 Tire Pressure Monitoring (TPM) System Sensor (left rear) B52 Tire Pressure Monitoring (TPM) System Sensor (left middle) B53 Tire Pressure Monitoring (TPM) System Sensor (left front) F24 Onboard Weighing (OBW) and Tire Pressure Monitoring (TPM) System 10-Amp Fuse R4 OBW/TMPS CAN 2 Termination Resistor W28 Tire Pressure Monitoring (TPM) System Antenna W34 Hydraulic Harness Ground X2 Articulation Harness-to-Rear Frame Harness 21-Pin Connector X3 Hydraulic Harness-to-Articulation Harness 21-Pin Connector X8 Cab Harness-to-Hydraulic Harness 31-Pin Connector X21 Chassis Control Unit (CCU) 48-Pin Connector (J1) X30 Fuse Block Switched Power Terminal Tire Pressure Monitoring (TPM) System— The TPM system is an electronic monitoring system using wireless technology to detect pressure and temperature of each tire. The controller receives and interprets radio frequency (RF) signals from a sensor located in each tire and warns the operator if low tire pressure and high temperature are detected. →NOTE: The TPM system must be enabled in the monitor menus for it to function. The TPM system can be enabled or disabled by accessing the MAIN MENU / SETUP / OPTIONS / MACHINE OPTIONS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Machine Options . (Group 9015-20.) →NOTE: The software version, software part number, and hardware part number for the tire pressure monitoring (TPM) system controller can be accessed in the MAIN MENU / DIAGNOSTICS / PARTS INFO / OPTIONAL PARTS / TPM submenu of the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics—Part Info . (Operator’s Manual.) TPM System Controller (A19) (power and ground)— When ignition power is ON, the TPM controller receives switched power from fuse (F24) at pin 2 on the TPM controller connector. The hydraulic harness ground (W34) provides ground to the TPM controller at pin 1. →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) When powered up, the TPM controller communicates with each tire sensor using RF signals via the TPM system antenna (W28). Even though the antenna connects directly to the TPM controller, the antenna is located at the right front of the rear frame, near the center of the machine. This is to provide equal reception for all tire sensors. The TPM system controller transmits tire data across the control area network (CAN) 2 data line to the chassis control unit (CCU) (A8). If the tire pressure drops to less than the alarm threshold setting, the CCU sends a message across the CAN 1 data line to the CAN monitor unit (CMU) (A7), causing the check tire pressure indicator to come on. →NOTE: For more information on the CCU circuit, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) For more information on the CAN circuits, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) For more information on the CMU, see CAN Monitor Unit (CMU) and Sealed Switch Modules (SSM) Circuits Theory of Operation . (Group 9015-15.) TPM System Sensors (B48—B53)— The tire sensors are located inside the tire near the valve stem and fastened to the OD of the rim with a spring clamp. Each tire sensor transmits data every 3 to 5 minutes. The tire sensor will also transmit when any of the following conditions <- Go to Section TOC
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occur: Pressure change of 21 kPa (0.21 bar) (3 psi) is detected. Sensor is programmed or checked by the JDG10928 SmartWave® Advanced Maintenance Tool. The tire pressure sensor outputs a signal for approximately 30 seconds when the INITIATE button on the special tool is pushed. The signal from each TPM sensor contains the following information: Sensor identification number. Actual tire pressure. Tire temperature. Sensor battery condition. →NOTE: Tire pressure, temperature, and battery condition can be viewed by accessing the MAIN MENU / OPERATION / TIRE INFORMATION submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Operation—Tire Information . (Operator’s Manual.) →NOTE: The tire pressure and temperature alarms can be enabled and disabled, and alarm thresholds set by accessing the MAIN MENU / SETUP / MACHINE SETTINGS / TPM SETUP submenu in the CMU menu structure. For more information, see TPM—Alarm Setup . (Group 9015-20.) →NOTE: Data for one or all sensors can be removed from the TPM controller memory by accessing the MAIN MENU / SETUP / MACHINE SETTINGS / TPM SETUP submenu in the CMU menu structure. For more information, see TPM—Delete Sensors . (Group 9015-20.) TPM system sensors must be programmed after any of the following conditions occur: Sensor and/or receiver replaced. One or more tires serviced, changed, or rotated. TPM System Sensor Programming— There are two methods for programming the tire sensors: Programming using the JDG10928 SmartWave ™ Advanced Maintenance Tool. Programming using sensor identification numbers. JDG10928 SmartWave® Advanced Maintenance Tool— The JDG10928 SmartWave® Advanced Maintenance Tool is a special handheld tool containing a display screen, selection buttons, an antenna, and a flash connection. The special tool has the ability to perform the following: Initiate: This function is used after the tire sensors have been installed to confirm whether the sensor positions were properly programmed in the TPM system controller. Pushing the INITIATE button while holding the special tool against the sidewall near the valve stem or adjacent to the sensor, causes the sensor to transmit the sensor ID, tire pressure, and temperature data. To program the sensors using the SmartWave® Advanced Maintenance Tool, see TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) Deactivate: This function is only used when the sensors are taken out of the tire and shipped back to the supplier. Pushing this button while holding the JDG10928 SmartWave® Advanced Maintenance Tool to the side of the sensor causes the sensor to stop transmitting. Learn: This function is used to provoke a learn transmission from the sensor in order to program the receiver. Each sensor has a unique ID that the TPM system controller uses to identify it. The ID can be entered into the CMU manually, or the sensor can identify itself and have the TPM system controller automatically “learn” the ID. For more information on manually entering the sensor IDs, see TPM—Programming Using Sensor Identification Numbers . (Group 9015-20.) The sensor can be automatically “learned” either by using the CMU or the JDG10928 SmartWave® Advanced Maintenance Tool. For more information on how the TPM system controller automatically “learns” the tire sensors, see TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.)
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Onboard Weighing (OBW) Controller Circuit Theory of Operation
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Onboard Weighing (OBW) Controller Circuit Schematic
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LEGEND: A5 A7 A8 A18 B4 B5 B6 B43 F24 H12 H13 H14 L3 R4 W31 W34 X2 X3 X8 X9 X21 X22 X23 X25 X26 X27 X28 X30 X70 X71 X72 X73 X74
Group 15: Sub-System Diagnostics
Transmission Control Unit (TCU) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Onboard Weighing (OBW) Controller Left Strain Gauge Right Strain Gauge Dump Body Position Sensor Output Speed Sensor OBW and TPMS 10-Amp Fuse Dump Body Under-Loaded Light (yellow) Dump Body Fully-Loaded Light (green) Dump Body Over-Loaded Light (red) Onboard Weighing (OBW) CAN Filter OBW/TPMS CAN 2 Termination Resistor Cab Ground Hydraulic Harness Ground Articulation Harness-to-Rear Frame Harness 21-Pin Connector Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J2) Chassis Control Unit (CCU) 53-Pin Connector (J3) Left Onboard Weighing (OBW) Load Lights 4-Pin Connector Right Onboard Weighing (OBW) Load Lights 4-Pin Connector Left Strain Gauge 4-Pin Connector Right Strain Gauge 4-Pin Connector Fuse Block Switched Power Terminal Transmission Control Unit (TCU) 21-Pin Connector Transmission Control Unit (TCU) 32-Pin Connector Transmission Control Harness-to-Clutch Control Harness 24-Pin Connector Clutch Control Harness-to-Retarder Control Harness 16-Pin Connector Retarder Control Harness-to-Output Speed Sensor 2-Pin Connector
Onboard Weighing (OBW) System— The OBW system is an electronically controlled system that detects payload weight. The system consists of the following major components: Onboard Weighing (OBW) Controller (A18) Left and Right Strain Gauges (B4 and B5) Chassis Control Unit (CCU) (A8) OBW Load Lights (H12, H13, and H14) The OBW controller contains an inclinometer that is used for detecting vehicle pitch and roll. For more information, see Inclinometer later in this theory. →NOTE: The software version, software part number, and hardware part number for the onboard weighing (OBW) controller can be accessed in the MAIN MENU / DIAGNOSTICS / PARTS INFO / OPTIONAL PARTS / OBW submenu of the CMU menu structure. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics—Part Info . (Operator’s Manual.) OBW Controller (A18) (power and ground)— When ignition is ON, the OBW controller receives switched power from fuse (F24) at pin 4 on the OBW controller connector. The hydraulic harness ground (W34) provides ground to the OBW controller at pin 3. →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) When powered up, the OBW controller measures payload using two strain gauges hardwired directly to the OBW controller. Strain Gauges (B4 and B5)— The OBW system uses the strain gauges to measure the weight distribution on the walking beam. Weight distribution correlates to the shape and location of the payload in the dump body. A 5-volt reference signal from pin 1 on the OBW controller is provided to the strain gauges at pin A. Return ground from pin 2 <- Go to Section TOC
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on the OBW controller is provided to the strain gauges at pin C. From pin B, the left strain gauge (B4) sends a signal to pin 11 on the OBW controller. From pin B, the right strain gauge (B5) sends a signal to pin 12 on the OBW controller. The OBW controller gathers raw data from the strain gauges and sends a signal via the CAN 2 data line to the CCU. For information on the CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) Chassis Control Unit (CCU) (A8)— The CCU interprets data received from the OBW controller to calculate the weight of the payload. Before the CCU can accurately determine the weight of the payload, a calibration procedure must be performed. See Onboard Weighing (OBW) Calibration (Group 9015-20.) →NOTE: The payload and OBW gain can be viewed as percentages by accessing the MAIN MENU / DIAGNOSTICS / READINGS / OBW submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—OBW Readings . (Group 9015-16.) For more information on the CCU, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) The CCU continuously calculates payload when in measuring mode. It also calculates offset (carryback). Measuring Mode: In measuring mode the weight of the payload is continuously calculated by the CCU. The calculated weight is sent to the CAN monitor unit (CMU) (A7) via the CAN 1 data line, where it can be displayed. When the calculated payload is less than 8000 kg (17 640 lb.), the CCU recognizes this condition as unloaded. The CCU communicates the unloaded condition via the CAN 1 data line to all other controllers. The CCU turns OFF the unloaded condition when the payload is above 10 000 kg (22 050 lb.) and will stay OFF until the payload goes below 8000 kg (17 640 lb.). The transmission control unit (TCU) (A5) sends speed and direction information via the CAN 1 data line to the CCU. When the transmission is shifted to reverse, the CCU starts a 30-second timer. The last calculated weight will be displayed on the CMU. After the 30 seconds has elapsed, the CCU will continue the weight calculation. When the signal from the dump body position sensor (B6) indicates the dump body position is more than 2%, the CCU stops the weight calculation and the last calculated weight will be displayed on the CMU. If the dump body position did not exceed 50%, the CCU will continue the calculation when the dump body position returns to below 2%. When the dump body position exceeds 50%, the CCU will recognize this as a tipping condition. When the CCU detects a tipping condition and the dump body position is then lowered to below 2%, the payload weight is zeroed and the offset (carryback) calculation is recalculated. For more information on the dump body position sensor, see Dump Body Control and Gear Limit Circuits Theory of Operation . (Group 9015-15.) Offset (Carryback) Calculation: The offset (carryback) calculation is the calculated zeroed weight of an empty dump body. The offset (carryback) calculation is measured whenever ignition is turned ON or after the dump body is raised above 50%, then lowered below the 2% position. The CCU will calculate the offset (carryback) calculation for 30 seconds before it will automatically begin measuring mode. While the offset (carryback) calculation is taking place, all load lights will flash 1/2 second ON and 1/2 second OFF. OBW Lights (H12, H13, and H14)— The CCU provides outputs to the following OBW lights: Dump Body Under-Loaded Light (Yellow) (H12): When the payload is less than 75% of the rated payload of the truck, the CCU sends pulsing current out pin J1 on CCU connector (X21) to the yellow OBW light (H12), causing the yellow light to flash at 1/2 second ON and 1/2 second OFF. All other OBW lights are off. When the ground speed is above 5 km/h (3 mph), the CCU turns off the yellow OBW light. When the payload is between 75—90%, the CCU sends continuous current to the yellow OBW light, causing the yellow light to be on continuously. All other OBW lights are off. Dump Body Fully-Loaded Light (Green) (H13): When the payload is between 90—110%, the CCU sends continuous current out pin C4 on CCU connector (X21) to the green OBW light, causing the green light to be on continuously. All other OBW lights are off. Dump Body Over-Loaded Light (Red) (H14): When the payload exceeds 110%, the CCU sends continuous current out pin 47 on CCU connector (X22) to the red OBW light, causing the red light to be on continuously. All other OBW lights are off. →NOTE: The status of the OBW lights outputs can be viewed as a live value by accessing MAIN MENU / DIAGNOSTICS / READINGS / CCU / OUTPUTS submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.)
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→NOTE: The CCU uses power from VP1 input to provide power to the OBW lights. For more information on the VP1 input and CCU outputs, see Chassis Control Unit (CCU) Outputs . (Group 9015-20.) Weigh System Factors— The efficiency and accuracy of the OBW system can be affected by the following: Load Position: Weight distribution on the strain gauges is less accurate when the payload is loaded too far forward or too far to the rear of the dump body. The payload must be distributed evenly. For payload distribution information, see Using Onboard Weighing (OBW) System . (Operator’s Manual.) Operating on a Slope: As ground slope increases or decreases from a level condition, distribution of weight is affected, thus resulting in a less accurate payload weight. When the machine is on an incline, while the offset (carryback) calculation is being measured, the weight of the dump body is not evenly distributed across the strain gauges. The greater the incline, the less accurate the offset (carryback) calculation will be. Offset (carryback) calculation is more accurate when the machine is on flat, level ground. When an incline of 5% or more is detected, the CCU will stop calculating the weight. It resumes calculating when vehicle incline is less than 5%. For more information, see Using Onboard Weighing (OBW) System . (Operator’s Manual.) Calibrated Versus Actual Payload: Actual payloads should be approximately equal to the calibrated payload for greatest accuracy. For example, if the truck is hauling a smaller payload than the calibrated payload, system accuracy will be reduced, and recalibration of the OBW system will be necessary to maintain accuracy. To recalibrate the OBW system, see Onboard Weighing (OBW) Calibration . (Group 9015-20.) Material Change: When material of different densities is being loaded in the dump body other than what the OBW system has been calibrated for, the accuracy of the OBW system will be affected. To recalibrate the OBW system, see Onboard Weighing (OBW) Calibration . (Group 9015-20.) Material Density Change: It is recommended that the OBW system be calibrated under normal working conditions and with normal payload material. For example, if the OBW system is calibrated using dry material, and this is the normal working condition, a payload of wet material may cause the dump body over-loaded light (red) to come on prematurely. Alternatively, if the OBW system is calibrated using wet material and is loaded with dry material, the fully-loaded light (green) may not come on. If material density changes, recalibration of the OBW system will be necessary to maintain accuracy. To recalibrate the OBW system, see Onboard Weighing (OBW) Calibration . (Group 9015-20.) Tailgate Installed or Removed: Whenever the tailgate is installed or removed, recalibration of the OBW system will be necessary. To recalibrate the OBW system, see Onboard Weighing (OBW) Calibration . (Group 9015-20.)
Pitch
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Roll Inclinometer— The inclinometer measures the pitch and roll of the machine. The OBW controller communicates the pitch and roll information to the CCU via the CAN 2 data line. Pitch: Measurement of fore-aft incline as a percentage. Roll: Measurement of side-to-side incline as a percentage. →NOTE: The pitch and roll measurements can be viewed as percentages in the MAIN MENU / DIAGNOSTICS / READINGS / OBW submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—OBW Readings . (Group 9015-16.) The CCU uses the pitch and roll percentage to control certain features on the machine. These features include: Electronic Brake Release: Aids in releasing the electronic brake system when machine is on an incline. For more information, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) Prevent Tip: If the roll percentage is 10% or more the CCU will prevent the dump body from rising. For more information on prevent tip, see Dump Body Control and Gear Limit Circuits Theory of Operation . (Group 9015-15.)
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Turbo Spin Down and Auto Shutdown Circuits Theory of Operation
Turbo Spin Down and Auto Shutdown Circuits Schematic
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LEGEND: A2 A3 A5 A7 A8 B15 B18 B25 B43 B5301 W34 X3 X9 X11 X13 X16 X21 X23 X70 X71 X72 X73 X74 Y8
Group 15: Sub-System Diagnostics
25-Button Sealed Switch Module (SSM) (OC3) Engine Control Unit (ECU) Transmission Control Unit (TCU) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Park Brake Pressure Switch Accelerator Pedal Sensor Dump Body Lever Position Sensor (if equipped) Output Speed Sensor Crankshaft Position Sensor Hydraulic Harness Ground Hydraulic Harness-to-Articulation Harness 21-Pin Connector Cab Harness-to-Hydraulic Harness 31-Pin Connector Engine Control Unit (ECU) Connector Engine Control Unit (ECU) Connector Cab Harness-to-Engine Harness 14-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Chassis Control Unit (CCU) 53-Pin Connector (J3) Transmission Control Unit (TCU) 21-Pin Connector Transmission Control Unit (TCU) 32-Pin Connector Transmission Control Harness-to-Clutch Control Harness 24-Pin Connector Clutch Control Harness-to-Retarder Control Harness 16-Pin Connector Retarder Control Harness-to-Output Speed Sensor 2-Pin Connector Electronic Brake Valve Solenoid
Turbo Spin Down— The turbo spin down mode is part of the controlled shutdown feature that is initiated by the operator. Turbo spin down allows the engine and turbocharger to cool before stopping the engine. Pushing the engine stop switch on the 25-button sealed switch module (SSM) (OC3) (A2) for less than 0.5 second when the transmission is in neutral and the park brake is applied will cause the system to immediately enter turbo spin down mode. Pushing the engine stop switch on the SSM for less than 0.5 second when travel speed is more than 3 km/h (2 mph) (output shaft speed more the 375 rpm) will cause the following sequence of events to occur: →NOTE: The TCU determines the transmission output shaft speed from the pulsed signal it receives from the output speed sensor (B43). The TCU then transmits the output shaft speed data to the CCU via the CAN data line. CCU sends a request to the transmission control unit (TCU) (A5) via the CAN for 100% retardation. 2. CCU sends a request to the engine control unit (ECU) (A3) to disable the throttle input from accelerator pedal sensor (B18). 3. When machine travel speed slows to less than 3 km/h (2 mph) (output shaft speed less the 375 rpm), the CCU sends a request to the TCU via the CAN to shift the transmission to neutral. 4. CCU electronically applies the service brakes by energizing electronic brake valve solenoid (Y8). 5. System enters turbo spin down mode. →NOTE: For more information on the park brake circuit, see Park Brake Circuit Theory of Operation . (Group 9015-15.) For more information on the TCU circuits, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-15.) For more information on the ECU circuits, see Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) For information on the CAN circuit, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) When in turbo spin down mode, the following events occur: The ECU communicates fuel consumption data to the CCU via the CAN data line. The CCU uses the last 2 minutes of fuel consumption data before turbo spin down mode is activated to determine the amount of time (0 to 120 seconds) to run the engine at slow idle before stopping the engine. A pop-up screen appears on the CMU showing the turbo spin countdown. <- Go to Section TOC
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When the countdown reaches zero, the ignition turns OFF and the engine stops. The length of the turbo spin countdown depends on machine usage. The maximum countdown time is 2 minutes. Bypassing Turbo Spin Down— An immediate engine shutdown can be performed that bypasses the turbo spin down mode. This is accomplished by pushing and holding the engine stop switch for longer than 0.5 second or pushing and releasing the engine stop switch twice. A diagnostic trouble code (DTC) will be generated when turbo spin down is bypassed. IMPORTANT: Prevent damage to turbocharger and engine. Do not bypass the turbo spin-down mode unless absolutely necessary. Turbo spin-down allows the engine temperature to normalize and provide enough time for the turbine in the turbocharger to slow down sufficiently before stopping the engine. Auto Shutdown— The auto shutdown feature allows the CCU to automatically turn off ignition power and stop the engine when the engine has been at slow idle for 2, 3, 5 10, or 15 minutes, depending on setting. →NOTE: The auto shutdown setting can be changed by accessing the MAIN MENU / SETUP / MACHINE SETTINGS / AUTO SHUT DOWN submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—Machine Settings . (Group 9015-16.) The ECU determines engine speed from the pulsed signal it receives from the crankshaft position sensor (B5301). The ECU then transmits the engine speed data to the CCU via the CAN data line. The CCU activates the auto shutdown timer whenever engine speed is at slow idle and the following conditions are met: Accelerator pedal position is less than 2%. Transmission is in neutral. Travel speed is 0.0 km/h (0.0 mph). Dump body is not being raised or lowered. Engine coolant temperature is more than 60°C (140°F). Exhaust aftertreatment cleaning is not active. Hydraulic calibration is not active. Onboard weighing (OBW) calibration is not active. Dump body sensor calibration is not active. Service mode is not active. The auto shutdown timer will reset if any of the following conditions occur: Accelerator pedal position is more than 2%. Transmission is shifted out of neutral. Travel speed becomes greater than 0.5 km/h (0.3 mph). Dump body is raised or lowered. Engine coolant temperature is less than 60°C (140°F). Exhaust aftertreatment cleaning is activated. Hydraulic calibration is activated. Onboard weighing (OBW) calibration is activated. Dump body sensor calibration is activated. Service mode is activated. When 30 seconds remain on the auto shutdown timer, a pop-up screen on the CMU will display a 30-second countdown. Once the shutdown time has elapsed, the following will occur: CCU sends a signal to the TCU via the CAN data line, requesting the transmission to be in neutral. CCU electronically energizes the electronic brake valve solenoid. CCU starts the hydraulic fan shutdown process. For information on the hydraulic fan shutdown, see Hydraulic Fan Control Circuits Theory of Operation . (Group 9015-15.) CCU sends a request to the 25-button SSM via the CAN data line to de-energize the ignition relay.
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JDLink™ Circuit Theory of Operation
JDLink™ System Circuit Schematic
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LEGEND: A3 A5 A7 A8 A6000 A6001 A6002 A6003 F13 F27 F52 G1 S1 W31 X9 X13 X14 X16 X21 X29 X30 X31 X70 X6001 X6002 X6005 X6014 X6015 X6016
Group 16: Monitor Operation
Engine Control Unit (ECU) Transmission Control Unit (TCU) CAN Monitor Unit (CMU) Chassis Control Unit (CCU) Modular Telematics Gateway (MTG) Control Unit GPS/Cellular Antenna Satellite (SAT) Module Control Unit (if equipped) Satellite Antenna (if equipped) JDLink ™ Unswitched Power 10-Amp Fuse JDLink™ Switched Power 5-Amp Fuse JDLink™ Return (ground) 5-Amp Fuse (inline) Battery (2 used) Battery Disconnect Switch Cab Ground Cab Harness-to-Front Frame Harness 31-Pin Connector Engine Control Unit (ECU) Connector Cab Harness-to-Front Frame Harness 21-Pin Connector Cab Harness-to-Engine Harness 14-Pin Connector Chassis Control Unit (CCU) 48-Pin Connector (J1) Fuse Block Unswitched Power Terminal Fuse Block Switched Power Terminal Cab Harness-to-JDLink Harness 12-Pin Connector Transmission Control Unit (TCU) 21-Pin Connector Cellular Antenna Connector GPS Antenna Connector Satellite Antenna Connector Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector Satellite (SAT) Module Control Unit 48-Pin Connector Satellite Adapter Harness-to-Universal JDLink™ Harness 6-Pin Connector
The JDLink ™ is a system used to communicate machine information and GPS location to an internet website using GPS and cellular connections provided by the modular telematics gateway (MTG) (A6000). The optional satellite (SAT) module control unit (A6002) allows wireless data transfer in remote areas where a cellular signal is not consistently available. For more information on the JDLink system, see System Overview . (TM114519.) MTG and SAT Power-Up (power and ground)— The MTG and SAT receive unswitched battery power from fuse (F13) at terminal M2 on MTG connector (X6014) and SAT connector (X6015). Ground is provided to the MTG at terminal F3 on MTG connector (X6014) from cab ground (W31). Ground is also provided to the MTG and SAT at terminal M1 on MTG connector (X6014) and SAT connector (X6015) through the inline 5-amp fuse (F52). When ignition is ON, current flows through fuse (F27) to terminal L1 on MTG connector (X6014), powering up the MTG controller. →NOTE: For switched power and unswitched power circuit information between the battery and the fuses, see 24Volt Power and Ground Circuits Theory of Operation . (Group 9015-15.) JDLink CAN Communication— The MTG communicates across the CAN 1 data line with the following controllers: Engine Control Unit (ECU) (A3) Transmission Control Unit (TCU) (A5) Chassis Control Unit (CCU) (A8) For more information on the CAN data line, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) The MTG stores the information collected from the machine controllers and transmits the information to the JDLink servers.
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Group 16 - Monitor Operation CAN Monitor Unit (CMU)—Service Mode From OPERATION menu, push NEXT button to highlight SITE LIMITS menu. Push SELECT button to display SITE LIMITS menu. There are two versions of the CAN monitor unit (CMU) menu structure: operator mode and service mode. Operator Mode— is used to change user preferences, view operational settings, and view diagnostic trouble codes (DTCs). See CAN Monitor Unit (CMU)—Main Menu . (Operator′s Manual.) →NOTE: Service Mode can be accessed from any menu within the CAN monitor unit (CMU). For additional information on the CMU, see CAN Monitor Unit (CMU)—Main Menu . (Operator’s Manual.) →NOTE: Service mode will stay active until ignition is cycled to OFF. Service Mode— provides additional items not available in operator mode. This feature allows a service technician to change operational settings and clear diagnostic trouble codes (DTCs). Service mode provides the technician a means to monitor functions and settings for diagnostic and testing purposes. To enter service mode, enable ignition by pushing the engine start switch once. Push and hold the MENU button on CMU for approximately 10 seconds until a pop-up temporarily displays stating “SERVICE MENU ENALBED.”
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CAN Monitor Unit (CMU)—Site Limits From OPERATION menu, push NEXT button to highlight SITE LIMITS menu. Push SELECT button to display SITE LIMITS menu. Multiple limits can be set. The owner can set four limits for machine speed and body height. The operator can set a dump body height limit. With both operator and owner limits enabled, the lower of the two limits will determine maximum dump body height. Rollover prevention features may also limit maximum height dump body can be raised. Owner body height limit can only be changed if owner PIN is available, if owner is already logged in, or service mode is active. Submenus under BODY HEIGHT LIMIT menu include: OPERATOR LIMIT— To enable operator dump body height limit, push NEXT button to highlight ENABLE, then push SELECT button. To disable operator body limit, push NEXT button to highlight DISABLE, then push SELECT button. A check mark (✓) will appear, indicating which selection is active. →NOTE: To set operator dump body height limit, the body does not have to be fully lowered, and the limit being set does not have to be enabled. To set a new operator body height limit, push NEXT button to highlight SET NEW LIMIT, then push SELECT button to activate. A screen will display, prompting operator to raise dump body to desired height. →NOTE: Do NOT set the body height limit with the dump body fully lowered. With body at desired height, push SELECT button to save. A screen will then display for 2 seconds, confirming that a new body height limit has been saved. Pushing MENU or BACK button during procedure will cancel process and restore previously saved body height setting. →NOTE: Owner body height limit can only be changed if owner PIN is available, if owner is already logged in, or if service mode is active. OWNER LIMIT— Push NEXT button to highlight OWNER LIMIT, then push SELECT button to activate. If owner is not already logged in, a screen will display, prompting user to enter owner PIN. If incorrect owner PIN is entered, a screen will display stating: NUMBER YOU ENTERED IS NOT A VALID PIN. This screen will display for 2 seconds and then return to BODY HEIGHT LIMIT menu. The process for setting owner body height limit is the same as for setting operator body height limit. Submenus under OWNER LIMIT menu include: BODY HEIGHT LIMIT— To enable or disable body limit, push NEXT button to highlight ENABLE/DISABLE. Push SELECT button to enter highlighted menu. A screen will appear stating: ENABLE DISABLE Push NEXT button to highlight desired setting. Push SELECT button to activate highlighted setting. A check mark (✓) will appear, indicating which selection is active. →NOTE: To set body height limit, the dump body does not have to be fully lowered, and limit being set does not have to be enabled. To set a new body height limit, push NEXT button to highlight SET NEW LIMIT, then push SELECT button to activate. A screen will display, prompting owner to raise dump body to desired height. →NOTE: Do NOT set the body height limit with the dump body fully lowered. With body at desired height, push SELECT button to save. A screen will then display for 2 seconds, confirming that a new body height limit has been saved. Pushing MENU or BACK button during procedure will cancel process and restore previously saved body height setting.
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CAUTION: Raising the dump body while traveling faster than 10 km/h (6.2 mph) increases risk of machine rollover. Prevent risk of rollovers, set dump body height limits appropriately for working conditions. BODY RESTRICTION— Body restriction limit is defaulted from the factory to be enabled. When enabled, and the dump body is raised past 2%, machine travel speed is limited to 10 km/h (6.2 mph). Some features may require the dump body to be raised while machine is traveling faster than 10 km/h (6.2 mph). For more information on dump body control and features, see Dump Body Control and Gear Limit Circuits Theory of Operation . (Group 9015-15.) To enable or disable the dump body speed limit: Within OWNER LIMITS menu, push the NEXT button until the BODY RESTRICTION menu is highlighted. Push SELECT button to enter BODY RESTRICTION menu. Push SELECT button again to enter ENABLE/DISABLE menu. A check mark (✓) will appear, indicating which selection is active. To change a selection, highlight desired setting and push SELECT button to activate. →NOTE: Owner personal identification number (PIN) is required to set rollover limits. If owner is not logged in, display will return to main menu. For more information, see CAN Monitor Unit (CMU)—Security . ROLL OVER LIMIT menu is also a function of service mode. To enable service mode, see CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) ROLL OVER LIMIT— Raising dump body when on a cross slope can potentially cause machine to roll over if center of gravity shifts outside left or right wheel base. To reduce potential risk of this happening, a user-settable slope limit can be enabled. When cross slope limit is exceeded, a warning statement will display and dump body height may be limited. Enter OWNER LIMITS menu. Push NEXT button to highlight ROLL OVER LIMIT menu. Submenus under ROLL OVER LIMIT include: ENABLE/DISABLE— Selecting this menu will allow the owner to enable or disable rollover prevention system. Using NEXT button, highlight desired setting. Push SELECT button to activate setting. A check mark (✓) will appear, indicating which selection is active. SET NEW LIMIT— Selecting this menu will allow the owner to enter a cross slope angle percent limit. When limit is reached or exceeded, a warning message will appear on display. If body height limit is enabled, dump body raise will be prohibited. A slope value of 100% corresponds to an angle of 45°. Minimum slope value is 5%; entering a number less than 5% will cause setting to default to 5%. Maximum slope value is 99% (screen only allows setting two digits). If more than two numbers are entered, the last two digits entered will be displayed and used. When desired slope percent is entered, push SELECT button to save setting. Pushing MENU or BACK button cancels function and returns to previous menu. AUTO DUMP BRAKE— Auto dump brake is defaulted from the factory to be enabled. With auto dump brake enabled and driveline assist active, the service brakes will latch when unloading the machine. For more information on dump body control, see Dump Body Control and Gear Limit Circuits Theory of Operation . (Group 9015-15.) See Dump Body Control . (Operator’s Manual.) Push NEXT button to highlight AUTO DUMP BRAKE menu. Push SELECT button to enter. Push NEXT button to highlight desired selection and push the SELECT button to activate selection. A check mark (✓) will appear indicating which selection is active. FACTORY RESET— The FACTORY RESET menu allows the technician to return the machine site limits to original factory settings.
CAN Monitor Unit (CMU)—Codes From DIAGNOSTICS menu, push NEXT button to highlight CODES menu. Push SELECT button to display CODES menu. Submenus on display include: 1. ACTIVE CODES 2. STORED CODES ACTIVE CODES— Displays up to twenty currently active diagnostic trouble codes (DTCs). When a DTC becomes inactive, it will be removed from active code list. Active codes are displayed in order of last occurrence, with most recent active code displayed first. For each active DTC, the following will be displayed: Suspect Parameter Number (SPN) Failure Mode Indicator (FMI) <- Go to Section TOC
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Text description of DTC Source controller of DTC (ECU, TCU, CMU, CCU, etc.) STORED CODES— Displays up to twenty of the most recent diagnostic trouble codes (DTCs) stored in CAN monitor unit (CMU). →NOTE: Diagnostic trouble codes (DTCs) are immediately stored in CMU upon becoming active, and therefore will appear in both ACTIVE CODES and STORED CODES lists. For each stored DTC, the following will be displayed: Suspect Parameter Number (SPN) Failure Mode Indicator (FMI) Text description of DTC Source controller DTC (ECU, TCU, CMU, CCU, etc.) Hour meter reading at first occurrence Hour meter reading at last occurrence Total number of occurrences CLEAR CODES— Allows the technician to clear all active and stored codes. Push NEXT button to highlight CLEAR CODES menu. Push SELECT button. A screen will appear stating: SELECT TO CLEAR BACK TO CANCEL Push SELECT button to clear all active and stored codes. A screen will appear stating: CODES CLEARED
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CAN Monitor Unit (CMU)—CCU Readings From DIAGNOSTICS menu, push NEXT button to highlight READINGS menu. Push SELECT button to display READINGS menu, push NEXT button to highlight CCU READINGS menu. Push SELECT button to display CCU READINGS menu. Chassis control unit (CCU) readings menu displays real time information of CCU sensors, switches, inputs, and outputs. CCU diagnostic information includes: INPUT SENSORS menu displays the following sensor information: BODY POSITION (V) BODY POSITION (%) BODY LEVER POS (V) BODY LEVER POS (%) FUEL SENDER (V) FUEL SENDER (%) HYDRAULIC TEMP (V) HYDRAULIC TEMP (° C) MAIN PUMP (kPa) SEC STEER (kPa) LEFT ENG FAN (RPM) RIGHT ENG FAN (RPM) FNT BRK TEMP (V) FNT BRK TEMP (° C) MID BRK TEMP (V) MID BRK TEMP (° C) REAR AXLE TEMP (V) REAR AXLE TEMP (° C) FNT AXLE LUBE (V) FNT AXLE LUBE (kPa) MID AXLE LUBE (V) MID AXLE LUBE (kPa) REAR AXLE LUBE (V) REAR AXLE LUBE (kPa) LEFT STRT HGHT (V) LEFT STRT HGHT (%) RIGHT STRT HGHT (V) RIGHT STRT HGHT (%) FRNT CDL PRES (V) FRNT CDL PRES (kPa) MID CDL PRES (V) MID CDL PRES (kPa) REAR CDL PRES (V) REAR CDL PRES (kPa) INPUT SWITCHES menu displays the following switch information: HEADLIGHT DIPS (OFF/ON) (momentary high beams) HI BEAM LIGHTS (OFF/ON) LOW BRAKE ACC (OFF/ON) HORN (OFF/ON) AC THERMO (OFF/ON) LEFT TURN (OFF/ON) RIGHT TURN (OFF/ON) HAZARD (OFF/ON) SECONDARY STEER (OFF/ON) PARK BRAKE PRES (OFF/ON) WIPER PARK POS (OFF/ON) BRAKE SWITCH 1 (OFF/ON) BRAKE SWITCH 2 (OFF/ON) STAIR LIGHT (OFF/ON) HYD FILTER REST CDL FLOOR (OFF/ON) SERVICE LIGHT (OFF/ON) FRONT AXLE FILT <- Go to Section TOC
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MID AXLE FILT REAR AXLE FILT POWER menu displays the following information: BATTERY (V) 12V CONVERTER (V) CCU OUTPUTS menu displays the following information: BODY UP (amp) BODY DOWN (amp) LEFT TURN LIGHTS (OFF/ON) RIGHT TURN LIGHTS (OFF/ON) LOW BEAMS (OFF/ON) HIGH BEAMS (OFF/ON) REV LIGHTS (OFF/ON) PARK LIGHTS (OFF/ON) WORK LIGHTS (OFF/ON) ART REV LIGHTS (OFF/ON) BRAKE LIGHTS (OFF/ON) BEACON (OFF/ON) HVAC BLOWER HIGH (OFF/ON) HVAC BLOWER MED (OFF/ON) HVAC BLOWER LOW (OFF/ON) HVAC PWM 1 (%) HVAC PWM 2 (%) HVAC PWM 3 (%) HVAC PWM 4 (%) AC CLUTCH (OFF/ON) SEAT HEATER (OFF/ON) BODY LEVER DETENT (OFF/ON) MIRROR DEMIST (OFF/ON) WIPER SPEED HIGH (OFF/ON) WIPER SPEED LOW (OFF/ON) WASHER PUMP (OFF/ON) HORN (OFF/ON) OBW YELLOW LIGHT (OFF/ON) OBW GREEN LIGHT (OFF/ON) OBW RED LIGHT (OFF/ON) BODY HEATING (OFF/ON) PARK BRAKE A (OFF/ON) PARK BRAKE B (OFF/ON) RGHT STRT UP (amp) RGHT STRT DWN (amp) LEFT STRT UP (amp) LEFT STRT DWN (amp) RIGHT REV FAN (OFF/ON) FRONT CDL (OFF/ON) MID CDL (OFF/ON) REAR CDL (OFF/ON) STAIR LIGHT (OFF/ON) SERVICE LIGHT (OFF/ON) BODY PRES RDCTN (amp) ELECT BRAKE VLVE (amp) FAN CUT (OFF/ON) LOAD HOLDING (OFF/ON) AXLE COOL CUT (OFF/ON) LEFT REV FAN (OFF/ON) RGHT ENG FAN (amp) LEFT ENG FAN (amp)
CAN Monitor Unit (CMU)—ECU Readings From DIAGNOSTICS menu, push NEXT button to highlight READINGS menu. Push SELECT button to display READINGS menu, <- Go to Section TOC
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push NEXT button to highlight ECU READINGS menu. Push SELECT button to display ECU READINGS menu. Engine control unit (ECU) readings menu displays real time information of ECU sensors, switches, inputs, and outputs. ECU diagnostic information includes: INPUT SENSORS menu displays the following information: ENG SPEED (RPM) ACCEL POS (%) ALT CHARGING (YES/NO) FUEL TEMP (° C) COOLANT LEVEL (%) COOLANT PRES (kPa) FUEL DEL PRES (kPa) ENG OIL PRES (kPa) COOLANT TEMP (° C) DPF OUT TEMP (° C) DPF SOOT LOAD (%) DPF ASH LOAD (%) BOOST PRES (kPa) BRAMTRC PRES (kPa) AIR FILTER PRES (kPa) INLET AIR TEMP (° C) CHARGE AIR TEMP (° C) INTAKE TEMP (° C) DIGITAL INPUTS menu displays the following information: ENG STARTER (OFF/ON) DPF FILTER STATE OTHER INPUTS menu displays the following information: SW BATT POWER (V) (battery voltage)
CAN Monitor Unit (CMU)—TCU Readings From DIAGNOSTICS menu, push NEXT button to highlight READINGS menu. Push SELECT button to display READINGS menu, push NEXT button to highlight TCU READINGS menu. Push SELECT button to display TCU READINGS menu. Transmission control unit (TCU) readings menu displays real time information of TCU sensors, switches, inputs, and outputs. TCU diagnostic information includes: INPUT SENSORS menu displays the following information: SUMP TEMP (° C) RETARDER TEMP (° C) TC OUT TEMP (° C) OUTPUT SHAFT (RPM) INPUT SHAFT (RPM) ACT RET TORQUE (%) DIGITAL INPUTS menu displays the following information: FILTER RESTRICTION LOCK UP CLUTCH (%) DIFF LOCK (%) OTHER INPUTS menu displays the following information: CURRENT GEAR (N, 1, 3, 4, 5, 6, 7, 8) SELECTED GEAR (N, 1, 3, 4, 5, 6, 7, 8) DRIVE ENGAGED (OFF/ON) SHIFT IN PROCESS (ON/OFF)
CAN Monitor Unit (CMU)—OBW Readings From DIAGNOSTICS menu, push NEXT button to highlight READINGS menu. Push SELECT button to display READINGS menu, push NEXT button to highlight OBW READINGS menu. Push SELECT button to display OBW READINGS menu. On board weighing (OBW) diagnostic information includes: PAYLOAD (%) OBW GAIN (%) <- Go to Section TOC
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PITCH (%) ROLL (%)
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CAN Monitor Unit (CMU)—Calibrations →NOTE: CALIBRATIONS menu is a function of service mode. To enable service mode, see CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.)
CAUTION: Avoid possible serious injury from machine movement. Clear area of all bystanders before performing calibrations. Area must have enough overhead clearance to raise dump body to full height of 7226 mm (23 ft 8.5 in.). Do not perform these calibrations within 4 m (13 ft) of high-voltage power lines. From DIAGNOSTICS menu, push NEXT button to highlight CALIBRATIONS menu. Push SELECT button to display CALIBRATIONS menu. Periodic calibrations of sensors will help machine operate properly. If a component is replaced, it is necessary to calibrate the related system before machine is returned to service. To calibrate sensors, follow instructions provided through the CMU. Submenus on display under CALIBRATIONS menu include: BODY— Minimum and maximum voltage outputs of dump body sensor shall be determined using a dump body calibration function. Minimum voltage corresponds to dump body in fully lowered position, and maximum voltage corresponds to fully raised position. Once calibrated, dump body sensor function computes position from 0 to 100% as voltage varies between minimum and maximum calibrated values. For body calibration procedure, see Dump Body Position Sensor Calibration . (Group 9015-20.) ARTIC ANGLE— Articulation calibration requires three calibration points: full left, full right, and center. During calibration, the technician will be prompted to steer to one of the calibration points. Chassis control unit (CCU) will store voltage value at calibration point. During operation, the CCU will use these calibration points to interpret articulation angle from center point. The following conditions must be met to initiate articulation angle calibration: Transmission in neutral. Park brake engaged. Engine running. When all conditions are met, follow instructions provided through the CMU to complete calibrations. STRUT— Whenever the struts or strut height sensors have been replaced or removed and installed, calibration of the struts must be performed. The following conditions must be met to initiate strut height sensor calibration: Transmission in neutral. Park brake engaged. Engine running. When all conditions are met, follow instructions provided through the CMU to complete calibrations. TRANSMISSION— The transmission clutches require periodic calibrations. The calibration process is initiated through the CMU. For more information, see Electronic Clutch Calibration . (Group 9015-20.) HYDRAULIC— The HYDRAULIC menu is used when testing or adjusting hydraulic pump margin pressure and maximum pressure. See Main Hydraulic Pump Margin and Maximum Pressure Test and Adjustment . (Group 9025-15.) SLOPE— Roll and pitch angles must be calibrated before first use. Periodic re-calibration may also be recommended as part of a periodic maintenance schedule. For slope calibration procedure, see Slope Sensor Calibration . (Group 9015-20.) OBW— On board weighing (OBW) provides real time measurements of both weight and volume of load. Weight calibration values are determined by correlating actual weight, as determined by a calibrated scale, to values provided by load sensors. For OBW calibration procedure, see On Board Weighing (OBW) Calibration . (Group 9015-20.)
CAN Monitor Unit (CMU)—Monitor From SETUP menu, push NEXT button to highlight MONITOR menu. Push SELECT button to display MONITOR menu. For more information on MONITOR menu in operator mode, see CAN Monitor Unit (CMU)—Main Menu—Setup—Monitor . (Operator’s Manual.) →NOTE: The following menus are a function of service mode. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) <- Go to Section TOC
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LANGUAGE: This menu allows the technician to set the CMU language. Available languages include: English French Spanish Russian A check mark (✓) will appear to indicate which selection is currently active. JOB TIMER: Job timer is a resettable hour meter that can be used to time tasks to the nearest tenth of an hour. Maximum time displayed is 9999.9 hours. Job timer stops and value is set to zero when it exceeds 9999.9 hours. Once started, job timer runs even when JOB TIMER menu is hidden. Job timer value is stored when engine stop switch is pressed and is retrieved when engine start switch is pressed again. To reset job timer: Navigate to JOB TIMER menu. See CAN Monitor Unit (CMU)—Main Menu—Setup—Monitor . (Operator’s Manual.) Using NEXT button, highlight JOB TIMER menu. Push SELECT button to reset. Push BACK button to exit. MAIN MENU ACCESS: This menu allows the technician to either show or hide the main menu. When the main menu is hidden, the operator is not able to view any menu items. Highlight desired setting and push SELECT button to activate. MONITOR DEFAULTS: →NOTE: Restoring monitor settings will reset ALL functions to default settings. This menu allows the technician to restore default monitor settings. Push SELECT button to restore default settings. Push BACK button to exit and save all previous settings.
CAN Monitor Unit (CMU)—Machine Settings From SETUP menu, push NEXT button to highlight MACHINE SETTINGS menu. Push SELECT button to display MACHINE SETTINGS menu. MACHINE SETTINGS menu is a function of service mode. To enter service mode, see CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) Submenus under MACHINE SETTINGS menu include: BODY HEAT— This menu allows the technician to set whether body heat function is active or inactive while machine is in reverse gear. AUTO SHUT DOWN— Allows the technician to set amount of time before auto shutdown function activates. It also allows auto shutdown function to be disabled. For more information on auto shutdown feature, see Turbo Spin Down and Auto Shutdown Circuits Theory of Operation . (Group 9015-15.) Automatic shutdown feature turns off ignition power and shuts down the engine after the machine has been idle for a preset period of time. Auto shutdown intervals include: 2 MIN 3 MIN 5 MIN 10 MIN 15 MIN TPM SETUP— This menu allows the technician to set up the tire pressure monitoring (TPM) system. For more information, see the following: TPM—Activating Tire Pressure Monitoring System . (Group 9015-20.) TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) TPM—Programming Using Sensor Identification Numbers . (Group 9015-20.) TPM—Cold Inflation Pressure (CIP) Setup . (Group 9015-20.) Tire Pressure Monitoring (TPM) System Theory of Operation . (Group 9015-15.)
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CAN Monitor Unit (CMU)—Machine Options →NOTE: OPTIONS menu is a function of service mode. To enter service mode, see CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) From SETUP menu, push NEXT button to highlight MACHINE OPTIONS menu. Push SELECT button to display MACHINE OPTIONS menu. OPTIONS menu allows the technician to enable or disable optional machine equipment through the CMU. It also enables the technician to change tire sizes and set operator alerts to prevent possible machine damage or injury. Submenus under MACHINE OPTIONS menu on display include: LIGHTING OPTIONS— BEACON LIGHT ARTIC LIGHT WORK LIGHTS PARK LICENSE LIGHT ALERT OPTIONS— AUTO HORN AT START FULL LOAD HORN ALERT IDL ALERT BODY UP ALERT CAB OPTIONS— HEATED MIRRORS HEATED SEAT BODY RAISE LEVER MACHINE OPTIONS— TPM (Tire Pressure Monitor) BODY HEAT TAIL GATE REVERSE FANS TIRE SIZE OPTIONS— 26.5R25 29.5F25 875/65R29
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CAN Monitor Unit (CMU)—Software Delivery From SETUP menu, push NEXT button to highlight SOFTWARE DELIVERY menu. Push SELECT button to display SOFTWARE DELIVERY menu. SOFTWARE UPDATE menu is for receiving Service ADVISOR ™ Remote (SAR) software downloads and installations to machine. Downloads can take place with engine running and machine operating. However, installation of software can only process if engine is not running and park brake is applied. If conditions exist that will not allow download or installation to happen, screens will appear on monitor advising what needs to be done in order to continue. From SOFTWARE DELIVERY menu, push SELECT button to display SOFTWARE UPDATE menu. →NOTE: To avoid delays, shut down engine, apply park brake, and read SOFTWARE TERMS AND CONDITIONS before continuing. (Find SOFTWARE TERMS AND CONDITIONS at beginning of this manual.) Push SELECT again and SOFTWARE UPDATE menu will display a series of screens depending on status of update and status of machine. If update is already downloaded, monitor will display the following screen: DOWNLOAD COMPLETE READY TO INSTALL After 3 seconds, monitor will then display a SOFTWARE LICENSE AGREEMENT screen, stating: PUSH SELECT TO ACCEPT THE TERMS AND CONDITIONS DEFINED IN THE OPERATOR′S MANUAL AND TO BEGIN LOADING THE NEW SOFTWARE UPDATE Once SELECT is pushed, installation will take place if all conditions are acceptable. A warning screen will appear for 5 seconds stating: WARNING DO NOT PRESS STOP BUTTON ONCE SOFTWARE UPDATE HAS STARTED The following screen will then appear: SOFTWARE INSTALLATION MAY TAKE 10 MINUTES SCREEN MAY BE BLANK When completed, monitor will display: SOFTWARE INSTALLATION COMPLETED SUCCESSFULLY PLEASE CYCLE POWER ——————————————————— The machine is set at the factory to auto approve software downloads. If the menu is set to notify when a download is available, the following will appear: NEW SOFTWARE AVAILABLE FOR DOWNLOAD 1. APPROVE DOWNLOAD 2. REJECT DOWNLOAD Push NEXT button to highlight desired selection. Push SELECT button to choose selection. Push BACK button to return to previous menu. If APPROVE DOWNLOAD is selected, a pop-up will appear on monitor for 5 seconds, stating: SOFTWARE DOWNLOADING NORMAL MACHINE OPERATION MAY CONTINUE (Monitor will go back to runtime screen after pop-up disappears, and normal machine operation may continue while software is being downloaded.) If REJECT DOWNLOAD is selected, a pop-up will appear on monitor for 5 seconds, stating: SOFTWARE DOWNLOAD REJECTED (Monitor will go back to runtime screen after pop-up disappears, and normal machine operation may continue.) <- Go to Section TOC
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——————————————————— If software download was sent when machine power was off, upon cycle start-up and initial display check, an alarm will beep and runtime screen will have a pop-up displayed, stating: SOFTWARE DOWNLOAD IS AVAILABLE “SELECT” TO DOWNLOAD “BACK” TO ASK LATER If software is ready to install upon cycle start-up and initial display check, an alarm will beep and runtime screen will have a pop-up displayed, stating: SOFTWARE READY TO INSTALL “SELECT” TO GO TO SOFTWARE UPDATE MENU “BACK” TO ASK LATER
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CAN Monitor Unit (CMU)—Security →NOTE: Pushing NEXT button will highlight the next category. Push SELECT button to enter that highlighted category. Push BACK button to return to the previous screen.
Numeric Keypad LEGEND: 1 2
Numeric Keypad Enter Key
The security menus can only be accessed if the owner personal identification number (PIN) is available or the owner is already logged in. The security feature is designed to impede theft or unauthorized use of the machine by preventing the engine from starting until the operator correctly enters a valid security code. The system provides for one master owner PIN and up to ten operator PINs. PINs can be from one to four numeric characters in length. Leading zeros are recognized. For example, 1, 01, and 001 are each valid and unique PINs. When security is enabled, the following occurs: When engine start switch is pressed, operator is prompted to enter a PIN on the numeric keypad (1). Valid PIN must be entered or engine will not start. When engine stop switch is pressed and engine shuts down, system automatically locks the vehicle controllers. Operator can restart engine within preset logout delay time. After delay time expires, a PIN must be entered to start engine. The machine owner can perform any of the following security system functions: <- Go to Section TOC
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Enable or disable security system. Change owner PIN. Manage and assign operator PINs. Manage and assign transport PIN. At the MAIN MENU, push NEXT button until SECURITY menu is highlighted. Push SELECT button to activate SECURITY menu. A screen will display, prompting the owner PIN to be entered. If the correct owner PIN is entered, the SECURITY submenus will be displayed. Submenus on display under SECURITY menu include: SECURITY SETTINGS MANAGE OPERATOR PINS MANAGE TRANSPORT PIN CHANGE OWNER PIN SECURITY SETTINGS menu allows the machine owner to disable or enable security system. The submenus on display under the SECURITY SETTINGS menu include: ENABLE SECURITY DISABLE SECURITY To enable security: Push NEXT button to highlight ENABLE SECURITY menu. Push SELECT button to display ENABLE SECURITY submenus. Submenus include: SECURE ON SHUTDOWN—Security will be enabled after machine has shut down. SECURE AFTER 5 MIN—Security will be enabled 5 minutes after the selection has been made. SECURE AFTER 60 MIN—Security will be enabled 60 minutes after the selection has been made A check mark (✓) will appear, indicating which selection is active. To disable security: At SECURITY SETTINGS menu, push NEXT button to highlight DISABLE SECURITY. Push SELECT button to disable the security system. A screen will appear, stating: WARNING! SECURITY HAS BEEN DISABLED. NO PIN IS REQUIRED TO START MACHINE! MANAGE OPERATORS PINS: The security system allows the owner to enter up to ten unique personal identification numbers (PINs) for operators. PINs can be added or deleted only by the owner. Operator PINs can be from one to four numeric characters. Leading zeros are acceptable and recognized. At SECURITY menu, push NEXT button to highlight MANAGE OPERATOR PINS menu. Push SELECT button to enter MANAGE OPERATOR PINS menu. A screen will appear, stating: OPERATOR PIN (displays operator PIN) NEXT - CHOOSE OPERATOR SELECT TO EDIT PIN BACK OR MENU TO EXIT A total of ten operator PINS are available; push NEXT button to select which operator PIN will be edited. When the desired operator PIN is displayed, push SELECT button to edit. Submenus that will be on display after an operator PIN has been selected include: CLEAR PIN—Allows the owner to clear selected operator PIN. ENTER NEW PIN—Allows the owner to set a new operator PIN. BACK TO CANCEL—Selecting will return the display to MANAGE OPERATOR PINS menu. Previous operator PIN information will remain active. MANAGE TRANSPORT PIN The owner can assign and manage a temporary transport personal identification number (PIN) for use by maintenance personnel during service or while transporting machine. When a transport PIN is assigned, owner also specifies a length of time from one to four hours that the PIN is valid. This time is actual machine operating hours, which counts down only when machine is running. The machine can be started any number of times using the transport PIN. Once the transport PIN time expires, the machine will <- Go to Section TOC
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continue to run until the engine stop switch is pressed. Thereafter, the engine will not restart unless a valid owner or operator PIN is entered. If an owner or operator PIN is entered before transport PIN time expires, the time is reset to zero. A valid transport PIN can be from one to four numeric characters in length. Leading zeros are acceptable and recognized. Access transport PIN management function as follows: At the SECURITY menu push, NEXT button to highlight MANAGE TRANSPORT PIN menu, then push SELECT button. MANAGE TRANSPORT PIN menu appears. Push NEXT button to highlight desired action. To clear transport PIN: Push NEXT button to highlight CLEAR TRANSPORT PIN. Push SELECT button to clear PIN. PIN is cleared and verification message pops up on screen. To change or enter new transport PIN: Push NEXT button to highlight CHANGE TRANSPORT PIN. Enter new transport PIN on sealed switch module keypad, then push SELECT button or push BACK button to exit without change. To set or change transport PIN time: Push NEXT button at TRANSPORT PIN menu to highlight CHANGE TRANSPORT PIN TIME. CHANGE TRANSPORT PIN TIME screen appears. Push NEXT button to increase valid time or BACK button to decrease time. Push SELECT button to store desired PIN time. CHANGE OWNER PIN The machine owner personal identification number (PIN) can be changed at any time using the following procedure. PINs can be from one to four numeric characters in length. Leading zeros are acceptable and recognized. At the SECURITY menu, push NEXT button to highlight CHANGE OWNER PIN menu. Push SELECT button to display. A screen will display, stating: ENTER NEW OWNER PIN SELECT TO SAVE BACK TO CANCEL When a new owner PIN is entered, push SELECT button. A screen will appear, stating: RE-ENTER NEW PIN SELECT TO VERIFY If the PIN entered matches, a screen will appear stating: CHANGE HAS BEEN SAVED If the PIN does not match a screen will appear for 2 seconds, stating: PIN DOES NOT MATCH OLD OWNER PIN HAS BEEN RESTORED The display will return to the CHANGE OWNER PIN menu.
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CAN Monitor Unit (CMU)—Exhaust Filter CAUTION: Servicing machine during exhaust filter auto cleaning can result in serious personal injury. Avoid exposure and skin contact with hot gases and components. During exhaust filter auto cleaning, the engine may run at elevated idle and hot temperatures for an extended period of time. Exhaust gases and exhaust filter components may reach temperatures hot enough to burn people and ignite or melt common materials.
→NOTE: Disabling exhaust filter auto cleaning is not preferred. Whenever possible, auto cleaning should be enabled to keep soot buildup to a minimum and to increase overall machine uptime. The EXHAUST FILTER menu displays the following submenus: SOOT LEVEL—For more information, see CAN Monitor Unit (CMU)—Main Menu—Exhaust Filter—Soot Level . (Operator’s Manual.) AUTO CLEANING—For more information, see CAN Monitor Unit (CMU)—Main Menu—Exhaust Filter—Auto Cleaning . (Operator’s Manual.) PARKED CLEANING—For more information, see CAN Monitor Unit (CMU)—Main Menu—Exhaust Filter—Parked Cleaning . (Operator’s Manual.) →NOTE: The following menus are a function of service mode. To enter service mode, see CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) SERVICE CLEANING—Allows the technician to activate an exhaust filter service cleaning function. AUTO CLEAN SETTINGS—Allows the technician to set default auto cleaning settings. Push NEXT button to highlight desired menu. Push SELECT button to display menu information. SERVICE CLEANING: When the exhaust filter restriction level reaches SERVICE level, engine power may be reduced until exhaust filter restriction is below a predetermined level. A service cleaning of the exhaust filter is required to reduce restriction. For more information on exhaust filter service cleaning, see Exhaust Filter . (Operator’s Manual.) To activate a service cleaning, push NEXT button until SERVICE CLEANING menu is highlighted. Push SELECT button to enter menu. To ensure the machine is in a predetermined safe state, the monitor will display a pop-up screen until the following conditions are met: 1. NEUTRAL 2. LOW IDLE 3. PARK Follow instructions provided by the CMU to activate exhaust filter service cleaning function. AUTO CLEAN SETTINGS: The AUTO CLEAN SETTINGS menu controls the state of the exhaust filter auto cleaning at machine power-up. Auto cleaning is set from the factory to be enabled. →NOTE: Disabling exhaust filter auto cleaning is not preferred. Whenever possible, auto cleaning should be enabled to keep soot buildup to a minimum and to increase overall machine uptime. The following settings are available for auto cleaning: DEFAULT PREVIOUS—auto cleaning remains in the last state selected by the operator at machine power-down. DEFAULT ENABLED—auto cleaning is enabled at machine power-up regardless of last state selected by operator. DEFAULT DISABLED—auto cleaning is disabled at machine power-up regardless of last state selected by operator. <- Go to Section TOC
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A check mark (✓) will appear, indicating which selection is active.
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Group 20 - References Electrical Component Specifications Item
Measurement
Specification
B6—Dump Body Position Sensor
Voltage (sensor lever rotated fully counterclockwise)
0.5 V
Voltage (sensor lever rotated fully clockwise)
4.5 V
Voltage (sensor lever centered between fully clockwise and fully counterclockwise position)
2.5 V
B7—Left Fan Speed Sensor
Resistance
150 ohms
B8—Right Fan Speed Sensor
Resistance
150 ohms
B9—Hydraulic Filter Restriction Switch
Pressure
21 000 kPa 210 bar 3046 psi
Voltage (sensor lever rotated fully counterclockwise)
0.5 V
Voltage (sensor lever rotated fully clockwise)
4.5 V
Voltage (sensor lever centered between fully clockwise and fully counterclockwise position)
2.5 V
Voltage (sensor lever rotated fully counterclockwise)
0.5 V
Voltage (sensor lever rotated fully clockwise)
4.5 V
Voltage (sensor lever centered between fully clockwise and fully counterclockwise position)
2.5 V
B12—Main Hydraulic Pressure Sensor
Voltage
0.5 V at 0 psi
B13—Secondary Steering Pressure Sensor (closes)
Voltage
B10—Right Side Height Sensor
B11—Left Side Height Sensor
4.5 V at 27 579.02 kPa (275.79 bar) (4000 psi) 0.5 V at 0 psi 4.5 V at 27 579.02 kPa (275.79 bar) (4000 psi) B15—Park Brake Pressure Switch
Pressure (opens)
15 500 kPa 155 bar 2248 psi
Pressure (closes)
11 600—12 700 kPa 116—127 bar 1682—1841 psi
B25—Dump Body Lever Position Sensor
Resistance
2.7—3.3 kilo-ohms (pins 1 and 2)
B26—Articulation Angle Sensor
Resistance
2.7—3.3 kilo-ohms (pins 1 and 2)
B27—Air Conditioner High/Low-Pressure Switch (normally Pressure (closes) open)
177—237 kPa 1.8—2.4 bar 26—34 psi
Pressure (opens)
180—220 kPa 1.8—2.2 bar 26.1—31.9 psi
B27—Air Conditioner High/ Low-Pressure Switch (normally closed)
Pressure (opens)
2500—2900 kPa 25—29 bar 362.6—420.6 psi
Pressure (closes)
1900—2300 kPa 19—23 bar 275.6—333.6 psi
B28—Air Conditioner Freeze Control Switch (S.N. —664056)
Temperature (opens)
1—3°C 34—37.5°F
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Item
Measurement
Specification
B28—Air Conditioner Freeze Control Switch (S.N. 664057— )
Temperature (opens)
0.5—1.7°C 33—35°F
Temperature (closes)
3.3—4.4°C 38—40°F
B35—Accumulator Low-Pressure Switch (closes)
Pressure
11 000 kPa 110 bar 1595 psi
B37—Fuel Level Sensor
Resistance
32.4 ohms with fuel level at 100% 42.4 ohms with fuel level at 93% 52.4 ohms with fuel level at 86% 62.4 ohms with fuel level at 79% 72.4 ohms with fuel level at 71% 85.4 ohms with fuel level at 63% 103.6 ohms with fuel level at 50% 119.8 ohms with fuel level at 40% 138 ohms with fuel level at 31% 153 ohms with fuel level at 25% 167 ohms with fuel level at 20% 180 ohms with fuel level at 16% 190 ohms with fuel level at 12% 239.9 ohms with fuel level at 0%
B38—Retarder Temperature Sensor
Resistance
62 kilo-ohms at 20°C (68°F)
B39—Transmission Sump Temperature Sensor
Resistance
62 kilo-ohms at 20°C (68°F)
B54—Hydraulic Temperature Sensor
Voltage
3.73 V at 40°C (104°F) 3.31 V at 50°C (122°F) 2.86 V at 60°C (140°F) 2.42 V at 70°C (158°F) 2 V at 80°C (176°F) 1.63 V at 90°C (194°F) 1.31 V at 100°C (212°F) 1.05 V at 110°C (230°F) 0.84 V at 120°C (248°F)
B55—Rear Axle Pressure Sensor
Voltage
0.08 V at 61.13 kPa (0.61 bar) (8.87 psi)—low saturation limit 0.11 V at 68.95 kPa (0.69 bar) (10 psi) 0.56 V at 172.37 kPa (1.72 bar) (25 psi) 1.15 V at 308.20 kPa (3.08 bar) (44.7 psi)—low calibration point 1.31 V at 344.74 kPa (3.45 bar) (50 psi) 2.06 V at 517.11 kPa (5.17 bar) (75 psi) 2.81 V at 689.48 kPa (6.89 bar) (100 psi) 3.56 V at 861.85 kPa (8.62 bar) (125 psi) 3.85 V at 928.72 kPa (9.29 bar) (134.7 psi)—high calibration point 4.31 V at 1034.21 kPa (10.34 bar) (150 psi) 4.75 V at 1137.64 kPa (11.38 bar) (165 psi) 4.93 V at 1175.79 kPa (11.76 bar) (170.53 psi)—high saturation limit
B58—Front Axle Differential Lock Pressure Sensor
Voltage
0.5 V at 0 psi 2.5 V at 2585.53 kPa (25.85 bar) (375 psi) 4.5 V at 5171.06 kPa (51.71 bar) (750 psi)
B59—Middle Axle Differential Lock Pressure Sensor
Voltage
0.5 V at 0 psi 2.5 V at 2585.53 kPa (25.85 bar) (375 psi) 4.5 V at 5171.06 kPa (51.71 bar) (750 psi)
B60—Rear Axle Differential Lock Pressure Sensor
<- Go to Section TOC
Voltage
0.5 V at 0 psi
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Group 20: References Measurement
Specification 2.5 V at 2585.53 kPa (25.85 bar) (375 psi) 4.5 V at 5171.06 kPa (51.71 bar) (750 psi)
B61—Front Axle Temperature Sensor
Voltage
4.975 V at -40°C (-40°F) 4.914 V at -20°C (-4°F) 4.748 V at 0°C (32°F) 4.378 V at 20°C (68°F) 3.730 V at 40°C (104°F) 2.867 V at 60°C (140°F) 2.004 V at 80°C (176°F) 1.315 V at 100°C (212°F) 0.841 V at 120°C (248°F)
B62—Middle Axle Temperature Sensor
Voltage
4.975 V at -40°C (-40°F) 4.914 V at -20°C (-4°F) 4.748 V at 0°C (32°F) 4.378 V at 20°C (68°F) 3.730 V at 40°C (104°F) 2.867 V at 60°C (140°F) 2.004 V at 80°C (176°F) 1.315 V at 100°C (212°F) 0.841 V at 120°C (248°F)
B63—Rear Axle Temperature Sensor
Voltage
4.975 V at -40°C (-40°F) 4.914 V at -20°C (-4°F) 4.748 V at 0°C (32°F) 4.378 V at 20°C (68°F) 3.730 V at 40°C (104°F) 2.867 V at 60°C (140°F) 2.004 V at 80°C (176°F) 1.315 V at 100°C (212°F) 0.841 V at 120°C (248°F)
B64—Front Axle Pressure Sensor
Voltage
0.08 V at 61.13 kPa (0.61 bar) (8.87 psi)—low saturation limit 0.11 V at 68.95 kPa (0.69 bar) (10 psi) 0.56 V at 172.37 kPa (1.72 bar) (25 psi) 1.15 V at 308.20 kPa (3.08 bar) (44.7 psi)—low calibration point 1.31 V at 344.74 kPa (3.45 bar) (50 psi) 2.06 V at 517.11 kPa (5.17 bar) (75 psi) 2.81 V at 689.48 kPa (6.89 bar) (100 psi) 3.56 V at 861.85 kPa (8.62 bar) (125 psi) 3.85 V at 928.72 kPa (9.29 bar) (134.7 psi)—high calibration point 4.31 V at 1034.21 kPa (10.34 bar) (150 psi) 4.75 V at 1137.64 kPa (11.38 bar) (165 psi) 4.93 V at 1175.79 kPa (11.76 bar) (170.53 psi)—high saturation limit
B65—Middle Axle Pressure Sensor
Voltage
0.08 V at 61.13 kPa (0.61 bar) (8.87 psi)—low saturation limit 0.11 V at 68.95 kPa (0.69 bar) (10 psi) 0.56 V at 172.37 kPa (1.72 bar) (25 psi) 1.15 V at 308.20 kPa (3.08 bar) (44.7 psi)—low calibration point 1.31 V at 344.74 kPa (3.45 bar) (50 psi) 2.06 V at 517.11 kPa (5.17 bar) (75 psi) 2.81 V at 689.48 kPa (6.89 bar) (100 psi) 3.56 V at 861.85 kPa (8.62 bar) (125 psi) 3.85 V at 928.72 kPa (9.29 bar) (134.7 psi)—high calibration point 4.31 V at 1034.21 kPa (10.34 bar) (150 psi) 4.75 V at 1137.64 kPa (11.38 bar) (165 psi)
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Section 9015 - ELECTRICAL SYSTEM Item
Group 20: References Measurement
Specification 4.93 V at 1175.79 kPa (11.76 bar) (170.53 psi)—high saturation limit
B69—Rear Axle Filter Restriction Switch
Voltage
0.5 V at 0 psi 2.5 V at 2585.53 kPa (25.85 bar) (375 psi) 4.5 V at 5171.06 kPa (51.71 bar) (750 psi)
B5101—Engine Oil Pressure Sensor
Voltage
0.19—0.42 V at 76 kPa (0.76 bar) (11.02 psi) 2.09—2.2 V at 290 kPa (2.9 bar) (42.06 psi) 4.37—4.83 V at 655 kPa (6.55 bar) (94.9 psi)
B5206—Manifold Air Temperature Sensor
Resistance
100—104 kilo-ohms at -40°C (-40°F) 29.1—29.8 kilo-ohms at -20°C (-4°F) 9.7—10.1 kilo-ohms at 0°C (32°F) 3.7—3.8 kilo-ohms at 20°C (68°F) 1598—1625 ohms at 40°C (104°F) 746—757 ohms at 60°C (140°F) 377—382 ohms at 80°C (176°F) 204—206 ohms at 100°C (212°F) 116.8—118.2 ohms at 120°C (248°F) 70.4—71.4 ohms at 140°C (284°F) 55.5—56.4 ohms at 150°C (302°F)
B5208—Engine Coolant Temperature Sensor
Resistance
657.5—670.9 ohms at 60°C (140°F) 237.2—246.4 ohms at 90°C (194°F) 174.3—181.8 ohms at 100°C (212°F)
B5209—Fuel Temperature Sensor
Resistance
96.1—105.5 kilo-ohms at -40°C (-40°F) 27.4—29.7 kilo-ohms at -20°C (-4°F) 9—9.7 kilo-ohms at 0°C (32°F) 3.4—3.5 kilo-ohms at 20°C (68°F) 1.43—1.49 kilo-ohms at 40°C (104°F) 657—684 ohms at 60°C (140°F) 327—333 ohms at 80°C (176°F) 174—178 ohms at 100°C (212°F) 98—101 ohms at 120°C (248°F)
B5301—Crankshaft Position Sensor
Resistance
2.7—3.4 kilo-ohms
B5302—Camshaft Position Sensor
Resistance
2.7—3.4 kilo-ohms
K1—Ignition Relay
Resistance
141 ohms at pins 1 and 2
R1—Engine Harness CAN 1 Termination Resistor
Resistance
120 ohms
R3—Cab CAN 2 Termination Resistor
Resistance
120 ohms
R4—OBW/TPMS CAN 2 Termination Resistor
Resistance
120 ohms
R7—Hydraulic Harness CAN 1 Termination Resistor
Resistance
120 ohms
Y2—Axle Cooling Cut-Off Solenoid
Resistance
28.8—35.2 ohms at 20°C (68°F)
Y7—Dump Body Heat Solenoid
Resistance
28.5 ohms at 20°C (68°F)
Y8—Electronic Brake Valve Solenoid
Resistance
8 ohms at 25°C (77°F)
Y11—Right Side Fan Cut-Off Solenoid
Resistance
28—35 ohms
Y15—Ether Start Aid Solenoid
Resistance
36.4 ohms at 20°C (68°F)
Y25—Load Holding Pilot Solenoid
Resistance
37—46 ohms
Y23—Dump Body Down Control Solenoid
Amperage
720 mA (fully raised position) 0 mA (fully lowered position)
Y24—Dump Body Up Control Solenoid
Amperage
720 mA (fully raised position) 0 mA (fully lowered position)
Y26—Dump Body Reduction Solenoid
Resistance
37—46 ohms
Y30—Dump Body Lever Detent Magnet
Resistance
481.5—588.5 ohms (pins 5 and 6)
Y38—Right Strut Up Solenoid
Resistance
32—36 ohms at 20°C (68°F)
Y39—Right Strut Down Solenoid
Resistance
32—36 ohms at 20°C (68°F)
Y40—Left Strut Up Solenoid
Resistance
32—36 ohms at 20°C (68°F)
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Group 20: References
Item
Measurement
Specification
Y41—Left Strut Down Solenoid
Resistance
32—36 ohms at 20°C (68°F)
Y45—Park Brake Release Solenoid 2
Resistance
32—36 ohms at 20°C (68°F)
Y51—Right Side Reversing Fan Solenoid
Resistance
37.6—45.8 ohms at 20°C (68°F)
Y52—Front Axle Differential Lock Apply Solenoid
Resistance
37.6—45.8 ohms at 20°C (68°F)
Y54—Rear Axle Differential Lock Apply Solenoid
Resistance
37.6—45.8 ohms at 20°C (68°F)
Y55—Front Axle Differential Lock Pressure Regulating Solenoid
Resistance
37.6—45.8 ohms at 20°C (68°F)
Y57—Rear Axle Differential Lock Pressure Regulating Solenoid
Resistance
37.6—45.8 ohms at 20°C (68°F)
Y60—Transmission Clutch A Solenoid
Resistance
11 ohms at 20°C (68°F)
Y61—Transmission Clutch B Solenoid
Resistance
11 ohms at 20°C (68°F)
Y62—Transmission Clutch C Solenoid
Resistance
11 ohms at 20°C (68°F)
Y63—Transmission Clutch D Solenoid
Resistance
11 ohms at 20°C (68°F)
Y64—Transmission Clutch E Solenoid
Resistance
11 ohms at 20°C (68°F)
Y65—Transmission Clutch F Solenoid
Resistance
11 ohms at 20°C (68°F)
Y66—Transmission Clutch R Solenoid
Resistance
11 ohms at 20°C (68°F)
Y67—Transmission Clutch V Solenoid
Resistance
11 ohms at 20°C (68°F)
Y68—Torque Converter Lockup (WK) Solenoid
Resistance
11 ohms at 20°C (68°F)
Y69—Retarder Solenoid
Resistance
11 ohms at 20°C (68°F)
Y70—Inter-Axle Differential Lock (IDL) Solenoid
Resistance
37.5—41.5 ohms at 20°C (68°F)
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Group 20: References
Service ADVISOR™ Connection Procedure →NOTE: The Controller area network (CAN) and software on this machine require connection using the electronic data link (EDL). Connection using a parallel port data module (PDM) will not allow Service ADVISOR ™ to operate properly. [1] LEGEND: 1 USB Cable 2 Electronic Data Link (EDL) 3 Diagnostic 9-Pin Connector Cable
EDL and Cables Connect EDL (2) to computer. [2] LEGEND: 4 Diagnostic 9-Pin Connector 5 Diagnostic 9-Pin Connector Cover
Diagnostic 9-Pin Connector and Cover Remove diagnostic 9-pin connector cover (5) from diagnostic 9-pin connector (4) located at left dash panel. [3] - Connect diagnostic 9-pin connector cable (3) to diagnostic 9-pin connector (4). [4] -
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Group 20: References
LEGEND: 6 Fault LED (red) 7 Power LED (green) 8 CAN Connection LED (yellow)
EDL LEDs Push engine start switch once. Power LED (8) must come on. [5] - The CAN connection LED (8) will come on when computer connects to the CAN data line. The CAN connection LED may flicker—this is normal. When the CAN connection LED is on, CAN data line is active and data is being transmitted. [6] - If computer cannot connect to the CAN data line and the CAN connection LED does not come on, check all cable connections to the machine and computer. Make sure the ignition is ON and the power LED is on. [7] IMPORTANT: To prevent damage to the EDL device, make sure the USB cable is not unplugged during this process. Keep USB cable plugged into the EDL device. If a problem is detected with the EDL device, the fault LED (6) will come on. This can also happen if the user is upgrading the firmware and the USB cable is unplugged during the upgrading process. When this happens, the EDL will need to be repaired.
Service ADVISOR™ Diagnostic Application The Service ADVISOR ™ application is what technicians use to diagnose and troubleshoot equipment. The application allows technicians to quickly and easily find information and solve equipment problems. The Service ADVISOR™ application provides access to manuals, the Dealer Technical Assistance Center (DTAC), real-time diagnostics, and system readings. The application also allows technicians to perform calibrations, run tests, and program controllers, when possible. The Connection - Readings shortcut bar within Service ADVISOR™ is used to connect to a machine. A connection allows a technician to take live system readings, create recordings, diagnose problems, calibrate, interactively test, and program controllers. With a connection established, the Readings menu allows a technician to add or remove a reading, set a readings baseline, and create and check recording triggers. With Service ADVISOR™ connected to a machine, the Diagnostics shortcut bar can be used to read machine diagnostic trouble codes. The diagnostic codes can then be reviewed by code number for specific details. When a diagnostic trouble code is opened, code information displays in a window similar to the way a manual would. The details of a diagnostic trouble code often are in a procedural format with links so the technician can work to correct the problem with the equipment while following the step-by-step process in the diagnostic trouble code details. See Service ADVISOR™ Connection Procedure . (Group 9015-15.) See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-15.)
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Group 20: References
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application [1] - Connect service laptop to machine. See Service ADVISOR™ Connection Procedure . (Group 9015-20.) [2] - Open Service ADVISOR ™ . [3] -
Service ADVISOR™ Start-Up Screen LEGEND: 1 Diagnostics Shortcut Bar 2 Connected Diagnostic Trouble Codes Folder From the shortcut bar, click Diagnostics to open diagnostics shortcut bar (1). [4] - Click Connected Diagnostic Trouble Codes folder (2). [5] -
Connection Options Dialog Box Select Connect to Model on the Connection Options dialog box, and click OK. <- Go to Section TOC
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Group 20: References
[6] -
Select Readings Connection Option Dialog Box LEGEND: 3 Adapter Drop-Down List 4 Selected Models List 5 Change Models Button On the Select Readings Connection Option dialog box, make sure that the appropriate adapter is displayed. If not, select the correct adapter from Current Adapter drop-down list (3). Options include: Electronic Data Link (EDL) Stand-alone USB Device Electronic Data Link (EDL) Using Bluetooth Parallel Data Module (PDM) Parallel Data Module (PDM) With USB Adapter [7] - Make sure that the correct machine is displayed in the selected models list (4). If not, click Change Models button (5). [8] - Click Connect to connect to machine. [9] -
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Group 20: References
Connected Diagnostic Trouble Codes LEGEND: 6 Connected Diagnostic Trouble Codes Tab 7 Readings Data Tab After Service ADVISOR™ connects to machine, Connected Diagnostic Trouble Codes tab (6) and Readings Data tab (7) are displayed. [10] - Click Connected Diagnostic Trouble Codes tab (6). Clicking on an underlined diagnostic trouble code displays a detailed description and diagnostic procedure for the diagnostic trouble code. [11] →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 to use this feature. Click Connected Diagnostic Trouble Codes tab (6) to select and view details for additional diagnostic trouble codes.
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Group 20: References
Intermittent Diagnostic Trouble Code (DTC) Diagnostics An intermittent diagnostic trouble code (DTC) is a DTC that periodically “goes away.” A loose terminal that intermittently does not make contact with its mating terminal is a likely cause of an intermittent DTC. Other intermittent DTCs may only be set under certain operating conditions such as heavy load or extended idle. Possible Causes of Intermittent DTCs Contact between terminals in connector. Check for loose, dirty, or partially disconnected connectors. See Connector Terminal Test . (Group 9015-20.) Connection between sensor or actuator and harness. Inspect the wiring routing looking for possible intermittent shorts to ground caused by contact with external parts (for example, rubbing against sharp sheet metal edges). Terminal-to-wire connection. Check for broken wires, damaged splices, and wire-to-wire shorts. Electromagnetic interference (EMI) from an improperly installed 2-way radio, etc., can cause erroneous signals to be sent to the controller. →NOTE: A controller is the component least likely to malfunction. Replace a controller only if the diagnostic procedure indicates that a controller replacement is necessary.
Diagnosing Intermittent DTCs If the diagnostic procedure indicates that the problem is intermittent, try to reproduce the operating conditions that were present when the DTC was active. Service ADVISOR ™ can be used to help locate intermittent problems using a function called Recording. The Recording function permits the recording of data parameter values during a diagnostic session. If a DTC is active during a certain diagnostic session, the parameters can be played back and observed to see what each applicable parameter′s value was when the DTC occurred. If a connection or wire is suspected to be the cause of the intermittent problem, clear DTCs, then check the connection or wire by wiggling it while watching Service ADVISOR™ and observe if the fault resets. The voltage measured at the controller input for most sensors can be monitored in Service ADVISOR™ as a data point. The minimum and maximum value of voltage (measured since the data point was selected) is displayed along with the current value of voltage. Check the minimum and maximum voltage columns in the data points screen after each section of the harness is wiggled to help isolate the problem location. After all causes for intermittent DTCs are repaired, clear codes, cycle ignition power, and check for active DTCs. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) If DTC reappears, see specific diagnostic procedure in Section 9001.
JDLink™ Connection Procedure →NOTE: The Modular Telematics Gateway (MTG) interfaces through the Service ADVISOR ™ Diagnostic Connector (X6015). For more information, see Service ADVISOR™ Connection Procedure . (Group 9015-20.)
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Group 20: References
Chassis Control Unit (CCU) Outputs The chassis control unit (CCU) uses three types of high-current output drivers to control functions that are hardwired to the controller. The high-current output drivers use low-voltage internal microcontrollers to control 24-volt signals. The three types of high-current output drivers are: 3.5-Amp 7.0-Amp 14.0-Amp Power sources for the CCU output drivers are as follows: VP1 — Switched power at 1-pin connector (X24) VP2 — Unswitched power from 10-amp fuse (F6) VP3 — Unswitched power from 20-amp fuse (F7) →NOTE: When the output is turned off due to a high-current condition, the status LED of the corresponding function on the SSM will show that the function is still on. A voltmeter can be used to detect the absence or presence of voltage on 3.5-amp drivers, but a test light is recommended on the 7-amp and 14-amp drivers. The 7-amp and 14-amp drivers turn off when an open condition exists or when the circuit is disconnected. Testing an open circuit using a voltmeter does not put sufficient load on the 7-amp and 14-amp drivers. The voltmeter measures approximately 20—24 volts due to a voltage leak. When a sufficient load is attached to the driver, the voltage drops to 0. 3.5-Amp Output— If the output is turned on, the CCU continues to drive the output so a technician can check voltage. Detection of a high-current condition occurs whenever the output is turned on and the driver detects an overload or over temperature-condition. When a high-current condition has been detected, the output turns off and resets only when the function or ignition is cycled OFF and ON. Exception: The output for the turn signals resets every time the output is cycled and is not based upon the turn signal or hazard switch being cycled. 3.5-Amp Output Usage 3.5-Amp Output Usage Component Description
Driver
Connector Pin
Power Source
Air Conditioner Clutch (Y22)
High
X22 (J2) - 10
VP1
Axle Cooling Cut-Off Solenoid (Y2)
High
X22 (J2) - 31
VP1
Beacon (H21)
High
X21 (J1) - H4
VP1
Body Down Solenoid (Y23)
Low
X21 (J1) - H3
VP1
Body Down Solenoid (Y23)
High
X21 (J1) - B4
VP1
Body Heater Solenoid (Y7)
High
X22 (J2) - 43
VP1
Body Lever Detent Magnet (Y30)
High
X22 (J2) - 42
VP1
Body Reduction Solenoid (Y26)
High
X21 (J1) - F4
VP1
Body Reduction Solenoid (Y26)
Low
X22 (J2) - 33
VP1
Body Up Solenoid (Y24)
Low
X21 (J1) - H2
VP1
Body Up Solenoid (Y24)
High
X21 (J1) - B4
VP1
Brake Lights (E10, E11)
High
X23 (J3) - 6
VP3
Differential Lock (CDL) Front Axle Solenoids (Y52, Y55)
High
X21 (J1) - D1
VP1
Differential Lock (CDL) Middle & Rear Axle Solenoids (Y53, Y54, Y56, Y57)
High
X22 (J2) - 41
VP1
Electronic Brake Valve (EBV) (Y8)
High
X21 (J1) - C1
VP1
Electronic Brake Valve (EBV) (Y8)
Low
X21 (J1) - G2
VP1
Fan Cut-Off Solenoid (Y11)
High
X23 (J3) - 7
VP1
Fan Low Pressure Left Side Solenoid (Y48)
High
X21 (J1) - E4
VP1
Fan Low Pressure Right Side Solenoid (Y49)
High
X22 (J2) - 44
VP1
Fan Reversing Left Side Solenoid (Y50)
High
X21 (J1) - K1
VP1
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Group 20: References
3.5-Amp Output Usage Fan Reversing Right Side Solenoid (Y51)
High
X21 (J1) - H1
VP1
Fan Speed Left Side Solenoid (Y9)
High
X21 (J1) - D4
VP1
Fan Speed Left Side Solenoid (Y9)
Low
X22 (J2) - 8
VP1
Fan Speed Right Side Solenoid (Y71)
High
X21 (J1) - G1
VP1
Fan Speed Right Side Solenoid (Y71)
Low
X21 (J1) - K2
VP1
HVAC Actuator #1 (M2)
High
X23 (J3) - 29
VP1
HVAC Actuator #4 (M6)
High
X23 (J3) - 53
VP1
HVAC Actuator #3 (M7)
High
X23 (J3) - 41
VP1
HVAC Actuator #2 (M8)
High
X23 (J3) - 17
VP1
Load Holding Pilot Solenoid (Y25)
High
X22 (J2) - 29
VP1
OBW Yellow Light (H12)
High
X21 (J1) - D4
VP1
OBW Green Light (H13)
High
X21 (J1) - C4
VP1
OBW Red Light (H14)
High
X22 (J2) - 47
VP1
Park Brake Release Solenoid 1 (Y46)
High
X22 (J2) - 45
VP1
Park Brake Release Solenoid 2 (Y45)
High
X22 (J2) - 46
VP1
Stairwell Light (E19)
High
X23 (J3) - 30
VP3
Strut Down Left Solenoid (Y41)
Low
X22 (J2) - 11
VP1
Strut Down Left Solenoid (Y41)
High
X22 (J2) - 17
VP1
Strut Up Left Solenoid (Y40)
Low
X22 (J2) - 48
VP1
Strut Up Left Solenoid (Y40)
High
X22 (J2) - 17
VP1
Strut Down Right Solenoid (Y38)
Low
X22 (J2) - 12
VP1
Strut Down Right Solenoid (Y38)
High
X22 (J2) - 53
VP1
Strut Up Right Solenoid (Y39)
Low
X22 (J2) - 13
VP1
Strut Up Right Solenoid (Y39)
High
X22 (J2) - 53
VP1
Turn Signal Left (E2, E6)
High
X23 (J3) - 18
VP3
Turn Signal Right (E1, E3)
High
X23 (J3) - 42
VP3
Windshield Washer Pump (M5)
High
X21 (J1) - G4
VP1
7.0-Amp Output— If the 7.0-amp output is turned on, the CCU continues to drive the output so a technician can check voltage. Detection of a high-current condition occurs whenever the output is turned on and the driver detects 8 amps or more for longer than 240 milliseconds. When a malfunction has been detected, the output will be turned off and automatically reset after 5 seconds. The CCU will retry turning on the output for 20 continuous counts. If the malfunction goes away before the 20 counts are up, the counter is reset. Turning the function off and back on again resets the counter. The CCU turns on the output again and tries to activate the function. 7.0-Amp Output Usage 7.0-Amp Output Usage Component Description
Driver
Connector Pin
Power Source
Articulation Backup/Work Lights (E17, E18)
High
X21 (J1) - L4
VP1
Backup Lights (E15, E16) and Backup Alarm (H1)
High
X22 (J2) - 1
VP1
Electric Horn (B3)
High
X23 (J3) - 3
VP3
Headlights (Low Beam) (E4, E7)
High
X22 (J2) - 6
VP1
Headlights (High Beam) (E5, E8)
High
X22 (J2) - 3
VP1
Heated Mirror Defrost (R12, R13)
High
X21 (J1) - M3
VP1
HVAC Fan Low Speed (M4)
High
X21 (J1) - M4
VP1
HVAC Fan Medium Speed (M4)
High
X21 (J1) - L3
VP1
Service Light (E21)
High
X23 (J3) - 1
VP3
Tail Lights (E10, E11) and License Plate Light (E12)
High
X22 (J2) - 5
VP1
Wiper Motor High (M3)
High
X22 (J2) - 30
VP1
Wiper Motor Low (M3)
High
X22 (J2) - 4
VP1
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Group 20: References
7.0-Amp Output Usage Work Lights (E28, E29)
High
X22 (J2) - 18
VP1
14.0-Amp Output— Whenever the 14.0-amp output is turned on and no current is detected, the CCU determines that an open circuit or short to power condition exists. The CCU continues to drive the output so a technician can check voltage. Detection of a high-current condition occurs whenever the output is turned on and the driver detects a current of 20 amps or more for longer than 80 milliseconds. When the malfunction has been detected, the output turns off and only resets when the function or ignition is cycled OFF and ON. 14.0-Amp Output Usage 14.0-Amp Output Usage Component Description
Driver
Connector Pin
Power Source
Heated Seat (R14, R15)
High
X23 (J3) - 5
VP1
HVAC Fan High Speed (M4)
High
X23 (J3) - 4
VP1
Exceptions (All Driver Outputs)— The CCU has the capability to detect driver malfunctions (open circuits, short circuits, etc.) and display diagnostic trouble codes (DTCs) for these malfunctions. There are certain situations that the CCU does not have the ability to detect the correct malfunction. Following is a summary of the known exceptions. The CCU cannot tell the difference between an open circuit and a short to power, or a short to ground and an overload. When changing the model in the CAN monitor unit (CMU), the audible alarm (buzzer) will activate if the setting was stored correctly. If the buzzer does not activate, the ignition must be cycled OFF and ON before changing options for them to be stored correctly. If the high speed and low speed wires are swapped on the front wiper motor, high speed will operate the wiper at low speed, low speed will operate like intermittent, and intermittent will not park correctly. A short to power can only be detected on a 7.0-amp driver output if the function is turned on. If a short to ground exists on a 7.0-amp output driver, the output will reset every 5 seconds up to 20 consecutive times. If a short to ground exists on a 14-amp output driver, the function must be turned off and then on to reset the output. If a malfunction exists for an output, that malfunction must be cleared by turning the function off and then on before a different fault for the same output can exist. If the CCU is not receiving the park signal from a wiper motor and the corresponding washer pump is activated, the wiper will cycle six times before stopping. If a wiper is stalled and high speed is selected, a park signal fault will result.
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Alternator Test
Common Alternator Circuit LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Battery Alternator Key Switch or Ignition Relay To Accessories ACC Alternator Excitation Diode Excitation Terminal (marked D+) B+ Exciter Diodes Positive Diodes Negative Diodes Stator Excitation Winding (field) Regulator AC Terminal (marked W) 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 [ Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage should be 14.1 VDC or greater. ]
. [3] - If voltage from previous steps is below 13.5 VDC [ Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage should be 14.1 VDC or greater. ]
, 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. <- Go to Section TOC
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[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 [ Note: For 24 V systems with maintenance free batteries, D+ and B+ voltage should be 28.2 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 [ Note: For 24 V systems with maintenance free batteries, D+ and B+ voltage should be 28.2 VDC or greater. ]
. [3] - If voltage from previous steps is below 27.5 VDC [ Note: For 24 V systems with maintenance free batteries, D+ and B+ voltage should be 28.2 VDC or greater. ]
, 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.
Relay Test
Relay De-Energized [1] - Remove relay. [2] - With relay de-energized, check for continuity across terminals 30, 87A, and 87 as shown. Replace relay if checks indicated the following: No continuity across terminals 30 and 87A Continuity exists across terminals 30 and 87 [3] -
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Relay Energized Energize relay by grounding terminal 85 and applying 24 volts to terminal 86. [4] - With relay energized, check for continuity across terminals 30, 87A, and 87 as shown. Replace relay if checks indicated the following: No continuity across terminals 30 and 87 Continuity exists across terminals 30 and 87A
Diode Test [1] - Remove diode. [2] - Check for continuity across diode terminals, then reverse test leads and repeat continuity check. If continuity is indicated in one check and not the other, diode is good. If continuity is indicated in both checks, diode is shorted, replace diode. If no continuity is indicated in either check, diode is open, replace diode.
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Controller Area Network (CAN) Circuit Test
Generic CAN Circuit Schematic LEGEND: 1 2 3 4 5 6 7 8
Controller 1 Controller 2 Service ADVISOR™ Connector Termination Resistor 1 Termination Resistor 2 CAN High Wire (yellow) CAN Low Wire (green) Grounded Shield Wire (black)
IMPORTANT: Avoid connector and connector terminal damage. Inserting test leads into harness connectors can damage the terminal and connector. When testing wire harnesses, always use spare mating terminals to connect test leads to connector terminals. See Connector Terminal Test . (Group 1600.) This machine uses two separate CAN networks, CAN 1 and CAN 2. Make sure that appropriate CAN network is tested. For more information, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.)
Controller Area Network (CAN) Diagnostics ( 1 ) System Check
Action: Switched power ON. Locate Service ADVISOR ™ connector and establish machine connection. See Service ADVISOR™ Connection Procedure . (Group 9015-20.) Does Service ADVISOR establish a connection?
Result: YES:Go to next step in this check. NO:Go to Service ADVISOR Fuse Test. <- Go to Section TOC
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Action: Do all controllers show up under connected controllers?
Result: YES: Go to CAN Termination Resistor Check . NO:Go to next step in this check.
Action: Is Service ADVISOR able to connect to any machine controllers?
Result: YES: Go to Controller Fuse Check . NO: Go to CAN Circuit Short to Ground Check . ( 2 ) Service ADVISOR Fuse Test
Action: Remove fuse for Service ADVISOR and check for continuity. For fuse location, see Fuse and Relay Specifications . (Group 9015-10.) Is continuity indicated?
Result: YES:Go to CAN Termination Resistor Check. NO:Replace Service ADVISOR™ fuse. ( 3 ) CAN Termination Resistor Check
Action: See Controller Area Network (CAN) Resistor Test . (Group 9015-20.) Is resistance within specification?
Result: YES:Go to CAN High Wire Voltage Check. NO:Replace termination resistor. ( 4 ) CAN High Wire Voltage Check
Action: IMPORTANT: Avoid connector and connector terminal damage. Inserting test leads into harness connectors without using spare mating terminal can damage harness. Switched power ON. Using a multimeter, measure voltage from pin C (CAN 1 high) to pin A (ground) and pin H (CAN 2 high) to pin A (ground) of Service ADVISOR connector (X1). Is voltage between 2.5 and 3.5 volts?
Result: YES:Go to CAN Low Wire Voltage Check. NO:Go to next step in this check. <- Go to Section TOC
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Action: Is system voltage present between pin C (CAN 1 high) to pin A (ground) and pin H (CAN 2 high) to pin A (ground) of Service ADVISOR connector?
Result: YES:A short circuit exists on CAN high wire. Check CAN high voltage one controller at a time to locate short circuit. NO:Go to next step in this check.
Action: Is zero voltage present between pin C (CAN 1 high) to pin A (ground) and pin H (CAN 2 high) to pin A (ground) of Service ADVISOR connector?
Result: YES: Go to CAN High Wire Circuit Check . NO:Remove one controller at a time and check voltage. When voltage is in range, check harness of disconnected controller for short circuits. Repair or replace harness as necessary. ( 5 ) CAN Low Wire Voltage Check
Action: Using a multimeter, measure voltage from pin D (CAN 1 low) to pin A (ground) and pin J (CAN 2 low) to pin A (ground) of Service ADVISOR connector. Is voltage between 2 and 3 volts?
Result: YES:Go to CAN High Wire Circuit Check. NO:Go to next step in this check.
Action: Is system voltage present between pin D (CAN 1 low) and pin A (ground) or pin J (CAN 2 low) and pin A (ground) of Service ADVISOR connector?
Result: YES:A short circuit exists on CAN low wire. Check CAN low voltage one controller at a time to locate short circuit. Repair or replace harness as necessary. NO:Go to next step in this check.
Action: Is zero voltage present between pin D (CAN 1 low) and pin A (ground) or pin J (CAN 2 low) and pin A (ground) of Service ADVISOR connector?
Result: YES: Go to CAN Low Wire Circuit Check . NO:Remove one controller at a time and check voltage. When voltage is in range, check harness of disconnected controller for short circuits. Repair or replace harness as necessary. ( 6 ) CAN High Wire Circuit Check
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Action: Using a multimeter, measure continuity between pin C (CAN 1 high) to pin A (ground) and pin H (CAN 2 high) to pin A (ground) of Service ADVISOR connector. Is continuity indicated?
Result: YES:A short to ground exists on CAN high wire. Check CAN high voltage one controller at a time to locate harness where short is located. Repair or replace harness as necessary. NO:Go to next step in this check.
Action: Using a multimeter, measure continuity between pin C (CAN 1 high) to machine ground and pin H (CAN 2 high) to machine ground. Is continuity indicated?
Result: YES:A short to ground exists on CAN high wire. Check CAN high voltage one controller at a time to locate harness where short is located. Repair or replace harness as necessary. NO:An open circuit exists on 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 1 low) to pin A (ground) and pin J (CAN 2 low) to pin A (ground) of Service ADVISOR connector. Is continuity indicated?
Result: YES:A short to ground exists on CAN low wire. Check CAN low voltage one controller at a time to locate harness where short is located. Repair or replace harness as necessary. NO:Go to next step in this check.
Action: Using a multimeter, measure continuity between pin D (CAN 1 low) to machine ground and pin J (CAN 2 low) to machine ground. Is continuity indicated?
Result: YES:A short to ground exists on CAN low wire. Check CAN low voltage one controller at a time to locate harness where short is located. Repair or replace harness as necessary. NO:An open circuit exists on CAN low wire. Repair or replace harness as necessary. ( 8 ) CAN Circuit Short to Ground Check
Action: Switched power OFF. Using a multimeter, measure continuity between pin D (CAN 1 low) to pin A (ground) and pin J (CAN 2 low) to pin A (ground) of Service ADVISOR connector. Using a multimeter, measure continuity between pin C (CAN 1 high) to pin A (ground) and pin H (CAN 2 high) to pin A (ground) of Service ADVISOR connector. <- Go to Section TOC
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Is continuity indicated?
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. NO:Go to next step in this check.
Action: Switched power OFF. Using a multimeter, measure continuity between pin D (CAN 1 low) to machine ground and pin J (CAN 2 low) to machine ground. Using a multimeter, measure continuity between pin C (CAN 1 high) to machine ground and pin H (CAN 2 high) to machine ground. Is continuity indicated?
Result: YES:A short to machine ground exists in CAN circuit. Disconnect each harness and check for continuity to machine ground. Repair or replace harness that has short to ground condition. NO:Go to CAN High/CAN Low Short Check. ( 9 ) CAN High/CAN Low Short Check
Action: Switched power OFF. Using a multimeter, check for continuity between CAN high and CAN low circuits. Is continuity indicated?
Result: YES:Short circuit between CAN high and CAN low wires. Check continuity between CAN high and CAN low circuits one controller at a time to locate harness where short is located. Repair or replace harness as necessary. NO: Go to Service ADVISOR Fuse Test . ( 10 ) Controller Fuse Check
Action: Remove fuse for missing controller(s). Check fuse(s) for continuity. Is continuity indicated in all fuses?
Result: YES:Go to Controller Check. NO:Replace fuse(s) that did not indicate continuity. ( 11 ) Controller Check
Action: Switched power OFF. Disconnect modular telematics gateway (MTG) control unit 48-pin connector (X6014). See JDLink™ Harnesses (W6002 and W6003) Component Location—If Equipped . (Group 9015-10.) Locate suspected controller(s). Using System Functional Schematic, Wiring Diagram and Component Location Master Legend, locate CAN wires and disconnect appropriate connector. Using a multimeter, measure resistance between CAN high and CAN low wires. Is resistance between 55 and 65 ohms? <- Go to Section TOC
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Result: YES:Go to next step in this check. NO:An open or short circuit exists in one of CAN wires. Work from controller back to main harness, checking CAN high and low wires for an open or short circuit.
Action: Switched power ON. Using System Functional Schematic, Wiring Diagram and Component Location Master Legend, check for power and ground at suspect controller(s). Is power and ground present?
Result: YES:Program malfunctioning controller. NO:An open or short circuit exists in circuit with no power or ground. Work from controller back to main harness, checking power and ground circuits for an open or short circuit. Repair or replace harness as necessary.
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Controller Area Network (CAN) Resistor Test Specifications SPECIFICATIONS Service ADVISOR ™ Connector (pins C and D) Resistance (CAN 1)
55—65 ohms
Service ADVISOR ™ Connector (pins H and J) Resistance (CAN 2)
55—65 ohms
CAN 1 Termination Resistor 1 (R1) and CAN 1 Termination Resistor 2 (R7) Resistance
110—130 ohms
CAN 2 Termination Resistor 1 (R3) and CAN 2 Termination Resistor 2 (R4) Resistance
110—130 ohms
The purpose of controller area network (CAN) resistor test is to check the CAN termination resistors on CAN 1 and CAN 2. The following resistance check can be made to ensure that CAN resistors for each CAN are in place and working properly. For more information on CAN networks, see Controller Area Network (CAN) Circuit Theory of Operation . (Group 9015-15.) [1] - Disconnect MTG control unit 48-pin connector (X6014). See JDLink™ Harnesses (W6002 and W6003) Component Location—If Equipped . (Group 9015-10.) [2] LEGEND: 1 C D H J X40
Cap Pin C Pin D Pin H Pin J Service ADVISOR Connector
Service ADVISOR Connector Remove cap (1) to access Service ADVISOR™ connector (X40). [3] - Using a multimeter, check resistance between pins (C and D) in Service ADVISOR connector. This checks the resistance on CAN 1. Item
Measurement
Specification
Service ADVISOR Connector pins (C and D)
Resistance (CAN 1)
55—65 ohms
[4] - Using a multimeter, check resistance between (pins H and J) in Service ADVISOR connector. This checks the resistance on CAN 2. Item
Measurement
Specification
Service ADVISOR Connector (pins H and J)
Resistance (CAN 2)
55—65 ohms
[5] - If resistance is not within specification, check resistance at pins A and B of CAN 1 termination resistors 1 and 2 (R1 and R7) and CAN 2 termination resistors 1 and 2 (R3 and R4). Item
Measurement
Specification
CAN 1 Termination Resistor 1 (R1) and CAN 1 Termination Resistor 2 (R7)
Resistance
110—130 ohms
CAN 2 Termination Resistor 1 (R3) and CAN 2 Termination Resistor 2 (R4)
Resistance
110—130 ohms
For CAN 1 termination resistor 1 (R1) location and pin information: For machines with engine model 6135HDW07, see Engine Harness (W25) Component Location and see Engine Harness (W25) Wiring Diagram . (Group 9015-10.) For machines with engine model 6135HDW05, see Engine Interface Harness (W26) Component Locationand see Engine Interface Harness (W26) Wiring Diagram. (Group 9015-10.) For CAN 1 termination resistor 2 (R7) location and pin information: See Hydraulic Harness (W13) Component Location and see Hydraulic Harness (W13) Wiring Diagram . (Group 9015-10.) <- Go to Section TOC
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For CAN 2 termination resistor 1 (R3) location and pin information: See Cab Main Harness (W12) Component Location and see Cab Main Harness (W12) Wiring Diagram . (Group 9015-10.) For CAN 2 termination resistor 2 (R4) location and pin information: See Rear Frame Harness (W20) Component Location and see Rear Frame Harness (W20) Wiring Diagram . (Group 9015-10.)
Hydraulic Pressure Switches Test
Brake Accumulator Low Pressure Switch (B35) Specifications SPECIFICATIONS Hydraulic Pressure Switches Test Brake Accumulator Low Pressure Switch (B35) Pressure
Contacts are closed at and above 11 000 kPa (110 bar) (1595.4 psi)
[1] - Remove pressure switch. [2] →NOTE: The contacts used on low accumulator pressure switch (B35) are normally closed. With no pressure applied to pressure switch, check for continuity across switch terminals. Replace switch if no continuity is indicated. [3] - Apply specified pressure to switch while checking for continuity across switch terminals. Replace switch if continuity is indicated. Item
Measurement
Specification
Brake Accumulator Low Pressure Switch (B35)
Pressure
Contacts are closed at and above 11 000 kPa (110 bar) (1595.4 psi)
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Hydraulic Pressure Sensors Test Essential Tools ESSENTIAL TOOLS JDG10466 Flex Probe Kit JDG1478 Digital Mulitmeter
Perform this procedure to test hydraulic pressure sensors, specifically rear axle pressure sensor (B55), front axle pressure sensor (B64), and middle axle pressure sensor (B65). This test will determine whether sensor output voltage is within specification at known system pressure.
Hydraulic Pressure Sensor Diagnostic Procedure ( 1 ) Pressure Sensor Test
Action: Switched power OFF. Disconnect sensor harness. For rear axle pressure sensor and middle axle pressure sensor, see Rear Frame Harness (W20) Component Location . (Group 9015-10.) For front axle pressure sensor, see Front Frame Harness (W11) Component Location . (Group 9015-10.) Use JDG10466 Flex Probe Kit to install lead between socket A (ground) of pressure sensor connector and pin A of pressure sensor. Flex Probe Kit JDG10466 Kit to make test leads Use JDG10466 Flex Probe Kit to install lead between socket B (5 V supply) of pressure sensor connector and pin B of pressure sensor. Set digital multimeter to measure voltage and connect test leads to pin C of pressure sensor and ground.
Pressure Sensor Test <- Go to Section TOC
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Switched power ON. Use multimeter to test voltage between: Digital Multimeter JDG1478 Device to read voltage Pin C of sensor and ground. Compare to specification. See Electrical Component Specifications . (Group 9015-20.) Is voltage within specification?
Result: YES:Check complete. NO:Sensor malfunction. Replace sensor.
Hydraulic Temperature Sensors Test
Hydraulic Temperature Sensor [1] - Remove sensor. [2] - Apply specified heat to sensor while checking resistance between sensor terminal and body of sensor. Replace sensor if not to specification. Item
Measurement
Specification
Temperature Sensor at 40°C (104°F)
Resistance
287.4 ohms
Temperature Sensor at 50°C (122°F)
Resistance
193.6 ohms
Temperature Sensor at 60°C (140°F)
Resistance
134.0 ohms
Temperature Sensor at 70°C (158°F)
Resistance
92.5 ohms
Temperature Sensor at 80°C (176°F)
Resistance
69.1 ohms
Temperature Sensor at 90°C (194°F)
Resistance
51.3 ohms
Temperature Sensor at 100°C (212°F)
Resistance
38.6 ohms
Temperature Sensor at 110°C (230°F)
Resistance
29.4 ohms
Temperature Sensor at 120°C (248°F)
Resistance
22.7 ohms
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Dump Body Position Sensor Test LEGEND: 1 Wire Connector 2 Linkage 3 Cap Screw and Nut (2 used) 4 Cap Screw and Nut 5 Support and Lever 6 Dump Body Position Sensor
Dump Body Position Sensor
Terminal Designations Specifications SPECIFICATIONS Dump Body Position Sensor (centered between full clockwise and full counterclockwise position) Voltage
2.5 V
Dump Body Position Sensor (sensor lever rotated fully clockwise) Voltage
4.5 V
Dump Body Position Sensor (sensor lever rotated fully counterclockwise) Voltage
0.5 V
[1] - Disconnect wire connector (1). [2] - Remove cap screw and nut (4) and disconnect linkage (2) from sensor lever. [3] →NOTE: It is necessary to remove sensor from mounting bracket to give the sensor lever full travel. Remove cap screws and nuts (3). [4] - Remove sensor by separating support and lever (5) from dump body position sensor (6). [5] - Connect wire connector (1) to sensor. [6] - Insert shaft of support and lever (5) into dump body position sensor (6) and rotate lever fully clockwise (as viewed from lever side of sensor). To view voltage reading, see CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Replace sensor if voltage is not to specification.
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Item
Measurement
Specification
Dump Body Position Sensor (sensor lever rotated fully clockwise)
Voltage
4.5 V
[7] - Rotate lever fully counterclockwise (as viewed from lever side of sensor). To view voltage reading, see CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Replace sensor if voltage is not to specification. Item
Measurement
Specification
Dump Body Position Sensor (sensor lever rotated fully counterclockwise)
Voltage
0.5 V
[8] - Rotate lever centered between full clockwise and full counterclockwise position (as viewed from lever side of sensor). To view voltage reading, see CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Replace sensor if voltage is not to specification. Item
Measurement Specification
Dump Body Position Sensor (sensor lever rotated centered between full clockwise and full counterclockwise)
Voltage
2.5 V
[9] - Install dump body position sensor (6), support and lever (5), cap screws and nuts (3). [10] - Connect linkage (2). [11] - Perform Dump Body Position Sensor Adjustment . (Group 9015-20.) [12] →NOTE: The dump body position sensor needs to be calibrated whenever the sensor, chassis control unit (CCU), or CAN monitor unit (CMU) is replaced. The sensor may also need recalibrating if the engine START switch is pushed to the ON position while sensor is disconnected. Calibrate sensor to the full dump body down and full dump body up positions. See Dump Body Position Sensor Calibration . (Group 9015-20.)
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Dump Body Position Sensor Calibration CAUTION: Avoid possible serious injury from machine movement. Clear area of all bystanders before performing test. Area must have enough overhead clearance to raise dump body to full height of 7226 mm (23 ft 8.5 in.). Do not perform this test within 4 m (13 ft) of high-voltage power lines.
→NOTE: The dump body must be allowed to go to maximum height. Disable any dump body height restriction before performing this procedure. See CAN Monitor Unit (CMU)—Site Limits . (Group 9015-16.) The minimum and maximum voltage outputs of the dump body sensor shall be determined using a dump body calibration function. The minimum voltage corresponds to the body in the fully lowered position, and the maximum voltage corresponds to the fully raised position. Once calibrated, the dump body sensor function computes the position from 0% to 100% as voltage varies between the minimum and maximum calibrated values. [1] - Enable Service Mode. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [2] - In the MAIN MENU, push the NEXT button until DIAGNOSTICS menu is highlighted, then push SELECT button. [3] - In the DIAGNOSTICS menu, push the NEXT button until CALIBRATION is highlighted, then push SELECT button. [4] - In the CALIBRATION menu, push the NEXT button until BODY is highlighted, then push SELECT. [5] - The following conditions must be met for the CMU to initiate dump body calibration: GEAR IN NEUTRAL PARK BRAKE SET ENGINE RUNNING If conditions are not met, the CMU will display actions required to proceed. [6] - When dump body calibration has successfully initiated, the following screen will display: BODY SENSOR CAL VERIFY BODY IS ALL THE WAY DOWN. THEN PRESS SELECT. -.- VOLTS Verify dump body is in the fully lowered position; check and record voltage reading. Item
Measurement
Specification
Dump Body Fully Lowered
Position
0% 4.5 V (maximum)
[7] - Press SELECT to save dump body fully lowered voltage. [8] - CMU will then prompt technician to raise dump body to fully raised position. Check and record voltage reading. Item
Measurement
Specification
Dump Body Fully Raised
Position
100 % 0.6—0.8 V
[9] - Press SELECT with dump body at fully raised position to save dump body fully raised voltage. [10] - CMU will prompt technician to lower dump body to stops, then press SELECT. If calibration is successful, CMU will display a screen stating: SENSOR CALIBRATION COMPLETE! PRESS SELECT TO EXIT <- Go to Section TOC
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If calibration fails, CMU will display a screen stating: SENSOR CALIBRATION FAILED! PRESS SELECT TO EXIT If previous screen appears during calibration process, it may be necessary to perform dump body position sensor adjustment. See Dump Body Position Sensor Adjustment . (Group 9015-20.)
Dump Body Position Sensor Adjustment [1] LEGEND: 1 Nut (2 used) 2 Mounting Bolt 3 Dump Body Position Sensor Linkage
Dump Body Position Sensor Linkage Loosen one or both nuts (1) on the dump body position sensor linkage (3). [2] - Remove mounting bolt (2). [3] - Remove linkage rod end from frame bracket. [4] - Adjust dump body position linkage until the fully lowered voltage reading is within specification. To view voltage reading see CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) [5] - Install linkage rod end and mounting bolt (2). Tighten nuts (1). [6] - Repeat steps 1—5 as necessary until voltage at both the fully lowered and the fully raised positions are within specifications. [7] - Perform dump body position sensor calibration procedure to verify correct adjustment of linkage. See Dump Body Position Sensor Calibration . (Group 9015-20.)
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Slope Sensor Calibration Roll and pitch angles must be calibrated before first use. Periodic re-calibration may also be recommended as part of a periodic maintenance schedule. [1] - Park machine on an open, flat surface. [2] - Access Service Mode menus. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [3] - In the MAIN MENU, push NEXT button until DIAGNOSTICS is highlighted. [4] - In the DIAGNOSTICS menu, push NEXT button until CALIBRATION is highlighted, then push SELECT. [5] - In the CALIBRATION menu, push NEXT button until SLOPE menu is highlighted, then push SELECT. [6] - With the machine parked on a level surface, three conditions must exist for calibration to continue. GEAR IN NEUTRAL PARK BRAKE SET ENGINE RUNNING When all conditions are met, calibration process continues as follows: →NOTE: In this calibration procedure it is required to return machine to the same position in opposite direction. It is recommended to use an appropriate marking device to locate machine. [7] - CCU will average roll and pitch values over a 5-second period, and temporarily save them. CMU will then prompt technician to move machine so it is pointed in opposite direction on same exact spot. Apply park brake to re-enable calibration process. Push SELECT button to continue. CCU will again average roll and pitch values over a 5-second period. [8] - Roll angle level position is the average of the two 5-second measured values. This value will be saved as zero roll angle calibration. [9] - Pitch angle level position is the average of the two 5-second measured values. This value will be saved as zero pitch angle calibration. [10] - Using new calibrated values, actual pitch and roll angles of calibration site will be displayed. If a pitch or roll angle of calibration site is greater than 2 degrees, the CMU will prompt technician to move to a different site and repeat calibration process. [11] - Once calibrated values are accepted, the CMU will prompt technician to move machine to original calibration site to verify values. When park brake is applied, push SELECT button to measure pitch and roll values for a 5-second period. If new 5second values are within 0.5% of previous average, calibration process is complete. [12] - When finished, push BACK button to return to the previous screen, or push MENU button to exit menus.
Steering Column Switch Test
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Steering Column Switch Legend
Steering Column Switch [1] - Remove steering column switch assembly. [2] - While operating switch functions, check for continuity across terminals as identified in the switch legend. [3] - Repair or replace as necessary. [4] - Replace switch assemble if continuity is not according to the switch legend.
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Transmission Solenoids and Sensors Tests
Transmission Control Circuit LEGEND: B38 B39
Retarder Temperature Sensor Transmission Sump Temperature Sensor
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X72 X73 Y60 Y61 Y62 Y63 Y64 Y65 Y66 Y67 Y68 Y69 Y70
Group 20: References
Transmission Control Harness-to-Transmission Valve Control Harness Connector Clutch Control Harness-to-Retarder Control Harness Clutch A Solenoid Clutch B Solenoid Clutch C Solenoid Clutch D Solenoid Clutch E Solenoid Clutch F Solenoid Clutch R Solenoid Clutch V Solenoid Torque Converter Lockup (WK) Solenoid Retarder Solenoid Inter-Axle Differential Lock (IDL) Solenoid
[1] - Disconnect transmission control harness-to-transmission valve control harness (X72). See Transmission Control Harness (W15) Component Location , and Transmission Control Harness (W15) Wiring Diagram . (Group 9015-10.) [2] →NOTE: Pins 10-14 are for Hall-effect type speed sensors. No test data is available for these sensors. Measure resistance of each component across the corresponding pins located on the transmission side of the connector. Item
Measurement
Specification
Clutch A Solenoid (Y60) (pins 1 and 23)
Resistance
11 ohms at 20°C (68°F)
Clutch B Solenoid (Y61) (pins 2 and 23)
Resistance
11 ohms at 20°C (68°F)
Clutch C Solenoid (Y62) (pins 3 and 23)
Resistance
11 ohms at 20°C (68°F)
Clutch D Solenoid (Y63) (pins 4 and 23)
Resistance
11 ohms at 20°C (68°F)
Clutch E Solenoid (Y64) (pins 19 and 23)
Resistance
11 ohms at 20°C (68°F)
Clutch F Solenoid (Y65) (pins 6 and 23)
Resistance
11 ohms at 20°C (68°F)
Clutch R Solenoid (Y66) (pins 5 and 23)
Resistance
11 ohms at 20°C (68°F)
Clutch V Solenoid (Y67) (pins 7 and 23)
Resistance
11 ohms at 20°C (68°F)
Torque Converter Lockup WK Solenoid (Y68) (pins 18 and 24)
Resistance
11 ohms at 20°C (68°F)
Retarder Solenoid (Y69) (pins 17 and 24)
Resistance
8.1—9.1 ohms at 20°C (68°F)
Inter-Axle Differential Lock (IDL) Solenoid (Y70) (pins 16 and 24)
Resistance
37.5—41.5 ohms at 20°C (68°F)
Transmission Sump Temperature Sensor (B39) (pins 9 and 22)
Resistance
62 kilo-ohms at 20°C (68°F)
Retarder Temperature Sensor (B38) (pins 8 and 21)
Resistance
62 kilo-ohms at 20°C (68°F)
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On Board Weighing (OBW) Calibration On board weighing (OBW) provides real time measurements of both weight and volume of load. Weight calibration values are determined by correlating actual weight, as determined by a calibrated scale, to values provided by load sensors. The OBW system is calibrated to obtain correct gain values so controller can convert raw data from strain gauges to an accurate weight. In some instances when less accuracy is required, gain values can also be reset to factory default settings. Refer to following appropriate procedure in this block: On Board Weighing (OBW) System—Calibration On Board Weighing (OBW) System—Restore Defaults The OBW system must be calibrated under certain conditions. These conditions include: Material Change: When material being loaded into dump body changes, OBW system requires calibration to maintain accuracy. Material Density Change: It is recommended that OBW system be calibrated under normal working conditions and with normal payload material. For example, if OBW system is calibrated using dry material, and this is normal working condition, a payload of wet material may cause dump body overloaded (red) light to come on prematurely. Alternatively, if truck is calibrated using wet material and is loaded with dry material, fully loaded (green) light may never come on. If material density changes, recalibration of OBW system will be necessary. Tailgate Installation or Removal: Whenever tailgate is installed or removed, OBW system requires calibration. →NOTE: To ensure accurate measurements, OBW calibrations must be performed on a flat surface for even weight distribution. On Board Weighing (OBW) System—Calibration [1] →NOTE: A calibrated scale is required to complete OBW calibration procedure. Access Service Mode in CAN monitor unit (CMU). See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [2] - In MAIN MENU, push NEXT button until DIAGNOSTICS is highlighted, then push SELECT button. [3] - In DIAGNOSTIC menu, push NEXT button until CALIBRATIONS is highlighted, then push SELECT button. [4] - In CALIBRATIONS menu, push NEXT button until ONBOARD WEIGHING is highlighted, then push SELECT button. [5] - In OBW WEIGHING CALIBRATION menu, CMU will show three options: SELECT SCALE UNITS SET EMPTY WEIGHT SET LOADED WEIGHT [6] - After scale units are selected, push NEXT button until SET EMPTY WEIGHT is highlighted, then push SELECT button. [7] - Drive machine onto a calibrated scale. Enter empty scale weight into CMU via numeric keypad on 25-button sealed switch module (SSM) (OC3). [8] - Load machine with a volume of dirt or other material, defined as a “SAE 2:1 Heaping Load.” →NOTE: If full load weight is greater than rated weight limit, rated limit is substituted. For most materials, dump body is sized to carry a “heaping load” without exceeding rated limit. [9] - Return machine to calibrated scale and weigh again. [10] - In OBW WEIGHING CALIBRATION menu, push NEXT button unit SET LOADED WEIGHT is highlighted. Enter loaded weight of machine into 25-button SSM (OC3). [11] - Drive truck off scale, then back onto scale. Again enter weight measured by scale. This is repeated until five <- Go to Section TOC
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measurements have been taken. These five readings are averaged and saved as full load weight. On Board Weighing (OBW) System—Restore Defaults [1] - Access Service Mode in CMU. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [2] - In MAIN MENU, push NEXT button until SETUP is highlighted, then push SELECT button. [3] - In SETUP menu, push NEXT button until MONITOR is highlighted, then push SELECT button. [4] →NOTE: Selecting monitor defaults will restore all monitor settings and site limits to factory defaults. In MONITOR menu, push NEXT button until MONITOR DEFAULTS is highlighted, then push SELECT button.
TPM—Activating Tire Pressure Monitoring System The tire pressure monitoring (TPM) system must be enabled in the CAN monitor unit (CMU) before the tire pressure sensor can be programmed. →NOTE: The tire pressure sensors must be programmed whenever any of these situations occur: Sensor and/or receiver were replaced. Tire was serviced. Tire was changed. Tires were rotated.
Activating Tire Pressure Monitoring (TPM) System [1] - Enable ignition power by pushing and releasing the engine start switch on the 25-button sealed switch module (SSM) (OC3). [2] - Access Service Mode in the CMU. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [3] →NOTE: When accessing the CMU menus, pushing the NEXT button will highlight the next category. Pushing the SELECT button will enter the highlighted category. Pushing the BACK button will return to the previous screen. In the MAIN MENU, push the NEXT button until SETUP is highlighted, then push SELECT button. [4] - In the SETUP menu, push the NEXT button until OPTIONS is highlighted, then push SELECT button. [5] - In the OPTIONS menu, push the NEXT button unit MACHINE OPTIONS is highlighted, then push SELECT button. [6] - In the MACHINE OPTIONS menu, highlight TPM. Push and hold SELECT button until a check mark appears next to TPM when enabled. [7] - When finished, push BACK button to return to the previous screen, or push MENU button to exit menus.
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TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool The tire pressure monitoring (TPM) system must be enabled in the CAN monitor unit (CMU) before the tire pressure sensors can be programmed. See TPM—Activating Tire Pressure Monitoring System . (Group 9015-20.) When the INITIATION button on the JDG10928 SmartWave ™ Advanced Maintenance Tool is pushed, the tire pressure sensor will transmit a signal for approximately 30 seconds. This is referred to as “pinging” the sensor. SmartWave ™ Advanced Maintenance Tool JDG10928 Monitor and calibrate tire pressure monitor (TPM) system. →NOTE: If the sensor identification number is known, the number can be entered manually using the CMU and the 25-button sealed switch module (SSM) (OC3). See TPM—Programming Using Sensor Identification Numbers . (Group 9015-20.) The tire pressure sensors must be programmed whenever any of these situations occur: Sensor and/or receiver were replaced. Tire was serviced. Tire was changed. Tires were rotated. For location of the TPM system components, see Rear Frame Harness (W12) Component Location . (Group 9015-10.) [1] - Enable ignition power by pushing and releasing the engine start switch on the 25-button SSM (OC3). [2] - Access Service Mode in the CMU. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [3] →NOTE: When accessing the CMU menus, pushing the NEXT button will highlight the next category. Pushing the SELECT button will enter the highlighted category. Pushing the BACK button will return to the previous screen. In the MAIN MENU, scroll down until SETUP is highlighted, then push SELECT button. [4] - In the SETUP menu, push the NEXT button until MACHINE SETTINGS is highlighted, then push SELECT button. [5] - In the MACHINE SETTINGS menu, push the NEXT button until TPM SETUP is highlighted, then push SELECT button. [6] - In the TPM SETUP menu, push the NEXT button until LEARN SENSORS is highlighted, then push SELECT button. [7] - In the LEARN SENSORS menu, either highlight LEARN ONE SENSOR or LEARN ALL SENSORS. [8] - To program all tire pressure sensors, perform the following: a. In the LEARN SENSORS menu, highlight LEARN ALL SENSORS. Push the SELECT button until the check mark appears next to LEARN ALL SENSORS. b. Power up the JDG10928 SmartWave Advanced Maintenance Tool. c. Go to the left-front tire. Hold the SmartWave tool against the sidewall, near the valve stem or adjacent to the sensor. Push the INITIATION button to “ping” the sensor. Wait 4—5 seconds while observing the SmartWave tool screen. When the tool receives the sensor transmission, the screen will display an eight-digit ID number and tire pressure within 14 kPa (2 psi) of actual tire pressure. The vehicle lights will flash and horn will activate to indicate that the controller has received the transmitted signal from the sensor. d. Repeat the procedure for the other five tires—left-middle, left rear, right rear, right middle, and right front, in that order. Move around the vehicle in a counterclockwise direction, until all sensors are programmed. e. When finished, push BACK button to return to the previous screen, or push MENU button to exit menus. <- Go to Section TOC
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[9] - To program one tire pressure sensor, perform the following: a. In the LEARN SENSORS menu, scroll down until the tire that is being programmed is highlighted. Push the SELECT button until the check mark appears next to LEARN ONE SENSOR. b. Power up the JDG10928 SmartWave Advanced Maintenance Tool. c. Go to the selected tire to be programmed. Hold the SmartWave tool against the sidewall, near the valve stem or adjacent to the sensor. Push the INITIATION button to “ping” the sensor. Wait 4—5 seconds while observing the SmartWave tool screen. When the tool receives the sensor transmission, the screen will display an eight digit ID number and tire pressure within 14 kPa (2 psi) of actual tire pressure. The vehicle lights will flash and horn will activate to indicate that the controller has received the transmitted signal from the sensor. d. Repeat steps a—c for all other tire pressure sensors that need to be programmed. e. When finished, push MENU button to return to the previous menu.
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TPM—Programming Using Sensor Identification Numbers The tire pressure monitoring (TPM) system must be activated in the CAN Monitor Unit (CMU) before the tire pressure sensors can be programmed. See TPM—Activating Tire Pressure Monitoring System . (Group 9015-20.) →NOTE: The tire pressure sensors must be programmed whenever any of these situations occur: Sensor and/or receiver were replaced. Tire was serviced. Tire was changed. Tires were rotated. →NOTE: If the sensor identification number is not known, the sensor can be programmed using the JDG10928 SmartWave® Advanced Maintenance Tool. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) [1] - Enable ignition power by pushing and releasing the engine start switch on the 25-button sealed switch module (SSM) (OC3). [2] - Access Service Mode in the CMU. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [3] →NOTE: When accessing the CMU menus, pushing the NEXT button will highlight the next category. Pushing the SELECT button will enter the highlighted category. Pushing the BACK button will return to the previous screen. In the MAIN MENU, push the NEXT button until SETUP is highlighted, then push SELECT button. [4] - In the SETUP MENU, push the NEXT button until MACHINE SETTINGS is highlighted, then push SELECT button. [5] - In the MACHINE SETTINGS menu, push the NEXT button until TPM SETUP is highlighted, then push SELECT button. [6] - In the TPM SETUP menu, push the NEXT button until ENTER SENSOR ID is highlighted, then push SELECT button. [7] - Push NEXT until the tire location to be programmed appears, then push the SELECT button. [8] - Enter the sensor ID using the numbered keys on the 25-button SSM (OC3), then push and hold SELECT button until the audible alarm beeps three times. [9] - When satisfied with the number inputted, push MENU button to return to the TPM SETUP menu. [10] - Repeat steps 6—8 for all other tire pressure sensors that need to be manually programmed.
TPM—Cold Inflation Pressure (CIP) Setup The COLD INFLATION PRESSURE (CIP) setup menu allows adjustment of alarm threshold for the front, middle, and rear tire pressures. When the tire pressure goes below the set alarm threshold, the tire pressure indicator on the CAN monitor unit (CMU) will come on. →NOTE: The tire pressure monitoring (TPM) system must be activated and programmed in the CMU before the CIP setup can be performed. See TPM—Activating Tire Pressure Monitoring System . (Group 9015-20.) [1] - Enable ignition power by pushing and releasing the engine start switch on the 25-button sealed switch module (SSM) (OC3). [2] - Access Service Mode in the CMU. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [3] -
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→NOTE: When accessing the CMU menus, pushing the NEXT button will highlight the next category. Pushing the SELECT button will enter the highlighted category. Pushing the BACK button will return to the previous screen. In the MAIN MENU, push the NEXT button until SETUP is highlighted, then push SELECT button. [4] - In the SETUP MENU, push the NEXT button until MACHINE SETTINGS is highlighted, then push SELECT button. [5] - In the MACHINE SETTINGS menu, push the NEXT button until TPM SETUP is highlighted, then push SELECT button. [6] - In the TPM SETUP menu, push the NEXT button until CIP SETUP is highlighted, then push SELECT button. [7] - In the CIP SETUP menu, push the NEXT button to the axle to be set up—FRONT AXLE, MID/REAR AXLE, then push SELECT button. [8] - Enter cold inflation pressure (CIP) recommended by the tire manufacturer using the numbered keys on the 25-button SSM (OC3). See Inspect Tires, Check Pressure . (Operator’s Manual.) Push and hold the SELECT button until the audible alarm beeps three times. [9] - When satisfied with the number inputted, push MENU button to return to the CIP SETUP menu. [10] - Repeat steps 7 and 8 as needed.
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TPM—Alarm Setup The tire pressure monitoring (TPM) system program must be activated in the CAN monitor unit (CMU). See TPM—Activating Tire Pressure Monitoring System . (Group 9015-20.) Temperature and pressure alarm must be set up and turned on for the TPM system to alert the operator of a problem with the system. [1] - To activate tire pressure monitoring (TPM) system, the CMU must be in SERVICE MODE. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-20.) [2] - With the CMU in SERVICE MODE, push the MENU button push the NEXT button until SETUP is highlighted, then push SELECT. [3] - Scroll to MACHINE SETTINGS and then push SELECT. [4] - In the MACHINE SETTINGS, push the NEXT button until TPM SETUP is highlighted, then push SELECT button. [5] - In the TPM SETUP, push the NEXT button until ALARM SETUP is highlighted, then push SELECT button. [6] - In the ALARM SETUP, scroll to one of the options and push SELECT: TEMPERATURE ALARM— Pressing SELECT toggles temperature alarm between ON and OFF. →NOTE: This is a temperature value entered by the operator. When temperature is above that value an alarm sounds. TEMPERATURE VALUE— Enter the temperature alarm threshold then push SELECT. LEVEL 1 PRESS ALARM— Pressing SELECT toggles pressure alarm between ON and OFF. →NOTE: This setup sounds the alarm when tire pressure is above or below the cold inflation pressure (CIP) recommended by the tire manufacturer by the percentage entered on this screen. See TPM—Cold Inflation Pressure (CIP) Setup . (Group 9015-20.) LEVEL 1 PRESS VALUE— Enter level 1 pressure value in percentage of full using the UP button to increase or DOWN button to decrease, then push SELECT. →NOTE: This setup sounds the alarm when tire pressure is critically below the cold inflation pressure (CIP) recommended by the tire manufacturer by the percentage entered on this screen. See TPM—Cold Inflation Pressure (CIP) Setup . (Group 9015-20.) LEVEL 2 PRESS VALUE— Enter level 2 pressure value in percentage of full using the UP button to increase or DOWN button to decrease, then push SELECT.
TPM—Delete Sensors The tire pressure monitoring (TPM) system program must be activated in the CAN monitor unit (CMU). See TPM—Activating Tire Pressure Monitoring System . (Group 9015-20.) Use this function to clear one or all sensors from the TPM system. [1] - To activate the tire pressure monitoring (TPM) system, the CAN monitor unit (CMU) must be in SERVICE MODE. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-20.) [2] - With the CMU in SERVICE MODE, push the MENU button. [3] - Scroll to MACHINE SETTINGS and push SELECT button. [4] - From MACHINE SETTINGS, push the NEXT button unitl TPM SETUP is highlighted, then push SELECT. [5] - From TPM SETUP, push the NEXT button until DELETE SENSORS is highlighted then push SELECT. [6] - From DELETE SENSORS, scroll to one of the options and push SELECT: DELETE ONE SENSOR— scroll to the tire to be deleted and push SELECT. DELETE ALL SENSORS— push SELECT again to delete all sensors. <- Go to Section TOC
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TPM—SmartWave® Advanced Maintenance Tool Diagnostics Essential Tools ESSENTIAL TOOLS JDG10928 SmartWave ™ Advanced Maintenance Tool
See JDG10928 SmartWave Advanced Maintenance Tool User Manual for more information. SmartWave ™ Advanced Maintenance Tool JDG10928 Monitor and calibrate tire pressure monitor system. Troubleshooting with JDG10928 SmartWave Advanced Maintenance Tool Troubleshooting with JDG10928 SmartWave Advanced Maintenance Tool The tool does not power up or turn off when the INITIATION button is pushed.
Replace batteries.
No tire pressure sensor data is received.
Make sure antenna is held within 559 mm (22 in.) of the tire pressure sensor in position before the INITIATION button is momentarily selected and make sure tool is held in that position for at least 4 to 5 seconds. Try to initiate and receive tire pressure sensor data from another tire pressure sensor.
The SETUP MENU button does not work.
Be sure to push and hold the button for at least 2 seconds.
The tool does not receive a sensor transmission after a sensor has been initiated into the system.
Make sure the tool’s antenna is held within 152 cm (6 in.) of the sensor when initiating sensor. This process may need to be repeated up to three times. If a sensor still will not respond, refer to the machine’s service manual for further diagnostic or repair information.
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TPM—Tire Pressure Sensor Remove and Install LEGEND: 1 2 3 4
Tire Pressure Sensor Tire Spring Clamp Valve Stem
Tire Pressure Sensor If removal of wheel from machine is necessary, see Wheel Remove and Install . (Group 0110.) IMPORTANT: Avoid tire pressure sensor damage on machines equipped with the tire pressure monitoring (TPM) system. Always follow these instructions, along with the instructions in the Tire Remove and Install procedure located in Group 0110, when removing tire from rim. To remove tire pressure sensor: [1] - Partially remove tire (2) from rim (one bead only), allowing enough room to access tire pressure sensor (1). For information on tire removal, see Tire Remove and Install . (Group 0110.) [2] →NOTE: If installed correctly, the spring clamp (3) and sensor will be located near the valve stem (4). Loosen spring clamp. Remove spring clamp and sensor assembly from rim. [3] - If tire is to be replaced or repaired, remove tire completely from rim. To install tire pressure sensor: [1] - If tire was removed, install one bead of tire on rim. [2] - Install spring clamp and sensor assembly onto rim so sensor is near the valve stem. [3] - Tighten spring clamp screw to 4 N·m (35 lb-in.). [4] - Install tire completely. See Tire Remove and Install . (Group 0110.) [5] - Install wheel on machine if removed. See Wheel Remove and Install . (Group 0110.) [6] →NOTE: The tire pressure sensors must be programmed whenever any of these situations occur: Sensor and/or receiver were replaced. Tire was serviced. Tire was changed. Tires were rotated. Program sensor. To program the sensor if sensor identification number is known, see TPM—Programming Using Sensor Identification Numbers . (Group 9015-20.) To program the sensor if sensor identification number is not known, see TPM—Programming Sensors with SmartWave® <- Go to Section TOC
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Advanced Maintenance Tool . (Group 9015-20.)
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Electronic Controllers Remove and Install The electronic controllers are located inside the cab, behind the left kick panel. See Cab Harness (W3) Component Location and see Transmission Control Harness (W4) Component Location . (Group 9015-10.) [1] - Turn battery disconnect switch to OFF position. [2] - Remove left kick panel. [3] - Disconnect harness connectors from controller to be removed. [4] - Remove controller mounting hardware and controller. [5] - Install controller and connect harness connectors. [6] - Install kick panel. [7] →NOTE: When an electronic controller is replaced, the new controller must be programmed according to the machine’s serial number. This will ensure the correct software and options are installed on the controller for that particular machine. The machine may run and operate without programming the new controller, but some features and options may not be available. Connect Service ADVISOR ™ to the machine. See Service ADVISOR™ Connection Procedure . (Group 9015-20.) [8] - Program controller. Use the following special instructions when replacing and/or programming the controllers: Engine Control Unit (ECU)— No special instructions. Chassis Control Unit (CCU)— Before replacing the CCU, always record the machine’s serial number, hour meter reading, and odometer reading. When programming the CCU, select either NEW or REPROGRAM in Service ADVISOR. If a new CCU is installed, selecting NEW allows the machine information to be retrieved from the CAN Monitor Unit (CMU). That way the machine data does not have to be manually entered. If an existing CCU is to be reprogrammed, select REPROGRAM. The machine data will be saved and automatically transferred into the new program. →NOTE: If the machine data was lost, it will be necessary to manually enter the machine hours and odometer reading. After programming the CCU, calibration of the following components may be necessary: Dump body position sensor. See Dump Body Position Sensor Calibration . (Group 9015-20.) Slope sensor. See Slope Sensor Calibration . (Group 9015-20.) Transmission Control Unit (TCU)— No special instructions. 25-Button Sealed Switch Module (SSM) (OC3)— No special instructions. 15-Button Seal Switch Module (SSM) (OC4)— No special instructions. JDLink ™ For information on replacing, transferring, or programming the JDLink controllers, see Transfer Terminal . (TM114519.) On Board Weighing (OBW) Controller— After the OBW controller is replaced or programmed, calibrate the OBW system. See On Board Weighing (OBW) Calibration . (Group 9015-20.) Tire Pressure Monitoring (TPM) Controller— After the TPM controller is replaced or programmed, reprogramming of tire pressure sensors is necessary. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool or see TPM—Programming Using Sensor Identification Numbers . (Group 9015-20.)
Program Monitor Display Unit (MDU) [1] -
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IMPORTANT: Avoid software programming issues. Chassis control unit (CCU) must be disconnected before programming MDU. →NOTE: The monitor display unit must be programmed to the same version as the CCU and outboard expansion unit (OEU). This will ensure the correct software and options are installed on the controller for that particular machine. The machine may run and operate without programming the new controller, but some features and options may not be available. Disconnect CCU. [2] - Program the MDU by performing the following: a. Connect Service ADVISOR ™ to the machine. See Service ADVISOR™ Connection Procedure . (Group 9015-20.) b. Turn ignition ON. c. Program MDU using Service ADVISOR ™ . d. When finished programming, cycle the ignition OFF, then back ON. [3] - Connect CCU.
Monitor Display Unit Remove and Install LEGEND: 1 Cap Screw (4 used) 2 Harness Connector 3 Harness Connector 4 Monitor Display Unit
Monitor Display Unit
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Monitor Display Unit Removal [1] - Turn key switch and battery disconnect switch to OFF position. [2] - Remove cap screws (1) and pivot steering wheel to full down position; tilt upward to access back side of monitor display unit (MDU) [3] - Disconnect harness connectors (2, 3). [4] - Remove monitor display unit (4). [5] - Repair or replace parts as necessary. [6] - Connect harness connectors (2, 3) to monitor display unit. [7] →NOTE: The monitor display unit must be programmed to the same version as the CCU and OEU . Program monitor display unit. See Program Monitor Display Unit (MDU) . (Group 9015-20.) [8] - Install cap screws (1).
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Connector Terminal Test The purpose of this test is to check for electrical terminal and connector problems. Terminal Basics— Terminals are typically made from a base metal that is plated with tin or an alloy. The plating material helps protect the base metal of the terminal from corroding. There are two main varieties of terminals; pins (male) and sockets (female). Male pins are inserted into female sockets to provide the electrical connection between wires or electrical devices. Female socket terminals typically contain one or more contact springs which provide firm contact points with the male pin terminal. Terminal Malfunctions— There are five common terminal malfunctions. 1. Corrosion—Corrosion or foreign material on terminals acts as a series resistance between the contact spring and the mating terminal. This series resistance can decrease the voltage on a circuit. Corrosion, liquids, or other foreign material in a connector may also provide a parallel resistance that permits current to flow between other terminals in the connector. This parallel path can increase or decrease the voltage on a circuit. Once terminals are corroded, they must be replaced. Scraping the layer of corrosion from the terminal will also remove any remaining plating material resulting in a rapid reappearance of the corrosion. 2. Loose Fit—A loose fit between pin and socket terminals may result in an intermittent open circuit. The loose fit is usually due to a damaged or worn contact spring inside the female socket terminal. Loose fitting terminals may be caused by misaligned terminals or by previous troubleshooting procedures where a probe was inserted into the female socket terminal to obtain a measurement. 3. Bent Terminals—Bent male pin terminals may cause an open circuit and possibly a short circuit with adjacent pins in the connector. Bent terminals are often caused by connector alignment or improper terminal crimping techniques. 4. Pushed Out Terminals—Terminals that are partially pushed out of the connector may cause an open circuit or an intermittent connection if the tip of the partially pushed out terminal makes electrical contact with the tip of the mating terminal. Pushed out terminals are caused by misaligned terminals or by terminals that were not fully seated in the connector during assembly. 5. Crimp Malfunctions—Terminals are crimped to wire ends to provide electrical and mechanical connection to the wire. The wire end may pull out of the terminal if not crimped correctly or if the wire has been pulled on with too much force. This results in an open circuit or an intermittent open circuit if the wire end makes contact with the terminal. When repairing or testing electrical connectors use the following guidelines to ensure proper electrical connection: Use specified extraction tools to remove terminals. Always use specified terminal as a replacement. The plating on mating terminals must be compatible or corrosion could occur. Always use specified seals for connectors that require them. Always use correct crimping tool to attach replacement terminals. After crimping a terminal to wire end, pull gently on the terminal to make sure it is securely crimped.
Connector Terminal Test Diagnostic Procedure ( 1 ) Terminal Visual Inspection
Action: Inspect terminals on both sides of the connection including a controller or sensor for the following problems: Corrosion on terminals or in connector. Water or other foreign material in connector. Bent terminals. Pushed out terminals. Are terminals OK?
Result: YES: Go to Terminal Test Loose Fit Check . NO:If terminal is pushed out or bent, replace or reinsert terminal.If terminals are corroded or foreign material is present, replace terminal. ( 2 ) Terminal Test Loose Fit Check
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
Action: Select proper mating terminal adapter from JDG10466 Flex Probe Kit. Flex Probe Kit JDG10466 Test terminal fit. Gently insert the male pin terminal fully into the female socket terminal without twisting or bending. Slowly pull the male pin terminal out of the female socket terminal. Is their noticeable tension when terminal adapter is withdrawn?
Result: YES: Go to Terminal Test Crimp Check . NO:Replace terminals with loose fit. ( 3 ) Terminal Test Crimp Check
Action: Remove connector back shell to access wire insertion end of connector (if applicable). Gently pull on each wire. Do any wire ends fall out of terminal?
Result: YES:Replace terminal(s) where wire ends fell out. NO:Checks complete.
Replace Metri-Pack® (Push Type) Connectors [1] LEGEND: A Connector Lock B JDG777 Terminal Extraction Tool C Connector Body Socket D Terminal E Locking Tab
Push Type Connector Disconnect the Metri-Pack ™ connector. [2] - Remove the connector lock (A), and mark wire colors for identification. [3] - Identify and record wire color locations with connector terminal letters. [4] →NOTE: JDG776 or JDG777 Terminal Extraction Tool are included in JT07195B Technicians Electrical Repair Kit. Insert JDG776 or JDG777 Terminal Extraction Tool (B) into connector body socket (C), pushing the terminal locking tab inward. Technicians Electrical Repair Kit JT07195B Used to extract Metri-Pack® terminals.
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
[5] →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. [6] - Replace terminal. Make sure locking tab (E) on the new terminal is in the outward position. [7] - Push terminal into connector body socket until terminal locks.
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
Replace Metri-Pack® Connectors LEGEND: A B
Tab 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 B
Wire 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.
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Group 20: References
[7] LEGEND: A B
Tab 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.
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Section 9015 page 359
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
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. JDG362 Extractor Tool for 16 to 18 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] <- Go to Section TOC
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
IMPORTANT: Avoid electrical malfunction. Install contact in proper connector location using correct size grommet.
Push Contact Push contact straight into connector body until positive stop is felt. [7] - Pull on wire and verify contact is locked in place.
Replace DEUTSCH® Rectangular or Triangular Connectors [1] →NOTE: Connector shown is the female half of a 4-pin square connector. Other similar styles of DEUTSCH ™ connectors can be serviced using the same procedure. LEGEND: 1 2
Connector Locking Wedge
Removing Locking Wedge Pull connector (1) apart. Inspect and clean connector seal and terminals. [2] →NOTE: Locking wedge shown can be removed using an O-ring pick or similar tool. Locking wedges in male connector halves can be pried out using a screwdriver. Remove locking wedge (2) from connector. [3] LEGEND: 3 Primary Locking Latches
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
Releasing Primary Latch
Removing Wire Release primary locking latch (3) next to the pin to be removed using a small screwdriver. [4] - Pull wire out from back of connector. [5] - Replace connector contacts as necessary. See Install DEUTSCH® Contact . (Group 9015-20.) [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.
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
Install DEUTSCH® Contact LEGEND: A B C
Selector Lock Nut Adjusting Screw
JDG360 Crimper [1] - Strip 6 mm (1/4 in.) insulation from wire. [2] →NOTE: JDG360 Crimper is included in JDG359 DEUTSCH ™ Electrical Repair Tool Kit. Adjust selector (A) on JDG360 Crimper for correct wire size. DEUTSCH® Electrical Repair Tool Kit JDG359 To repair DEUTSCH® electrical connectors. [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. LEGEND: A B C D
Contact Cover Lock Nut Adjusting Screw
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 indenters while crimping.
Crimp <- Go to Section TOC
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Group 20: References
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 WEATHER PACK® Connector
Terminal Contact [1] - Identify and record wire color locations with connector terminal letters. [2] - Open WEATHER PACK ™ connector body. [3] →NOTE: JDG364 Extraction Tool is included in JT07195B Technicians Electrical Repair Kit. Insert JDG364 Extraction Tool over terminal contact in connector body. Technicians Electrical Repair Kit JT07195B Used to extract WEATHER PACK® terminals. [4] - Fully seat extractor tool 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. [5] -
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
IMPORTANT:
Connector Body Carefully spread contact lances to ensure 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. [6] - Pull on wire slightly to be certain contact is locked in place. [7] - Transfer remaining wires to correct terminal in new connector. [8] - 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] -
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
→NOTE: Contacts have numbered identification for two sizes of wire: #15 for 14 to 16 gauge wire #19 for 18 to 20 gauge wire Put proper size WEATHER PACK ™ contact on wire and crimp in place with a “W” type crimp, using JDG783 Packard Crimping Tool. Packard Crimping Tool JDG783 Use to crimp WEATHER PACK® terminals. [4] →NOTE:
Contact Installation LEGEND: A Sleeve B Pin Proper contact installation for sleeve (A) and pin (B) is shown. Fasten cable seal to contact using JDG783 Packard Crimping Tool.
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
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] -
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
LEGEND: 1 4
Extraction Tool 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.
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Section 9015 page 368
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
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). <- Go to Section TOC
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
[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.)
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Section 9015 page 370
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
Repair 32 and 48 Way CINCH™ Connectors [1] LEGEND: A B C D
Tab Locking Cam Cover Locks 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
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Section 9015 page 371
Terminal Lock
TM12406-OPERATION AND TEST MANUAL
Section 9015 - ELECTRICAL SYSTEM
Group 20: References
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 B C D E
20 Gauge Holes 16 and 18 Gauge Holes Holes Terminal Hole 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
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Section 9015 - ELECTRICAL SYSTEM
Group 20: References
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. <- Go to Section TOC
Section 9015 page 373
TM12406-OPERATION AND TEST MANUAL
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.
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Section 9020 page 374
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TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Section 9020 - POWER TRAIN Table of contents Group 05 - Theory of Operation ............................................................................................................. 1 Transmission Control System ............................................................................................................... 1 Transmission Cross Sectional Diagram ................................................................................................. 2 Transmission System Schematic .......................................................................................................... 5 Torque Converter Operation ................................................................................................................. 8 Transmission Clutch Engagement ........................................................................................................ 9 Transmission Retarder Operation ....................................................................................................... 16 Transmission Inter-Axle Differential Lock (IDL) Operation .................................................................. 19 Cross-Axle Differential Lock (CDL) Operation ..................................................................................... 21 Service Brake System Operation ........................................................................................................ 23 Park Brake Operation ......................................................................................................................... 29 Suspension System Operation ............................................................................................................ 31 Group 15 - Diagnostic Information ...................................................................................................... 32 Transmission External Components ................................................................................................... 32 Power Train Component Location ....................................................................................................... 34 Service Brake Circuit Component Location ......................................................................................... 35 Axle Breather Leaking Diagnostic Procedure ...................................................................................... 35 Final Drive Overheating Diagnostic Procedure ................................................................................... 36 Final Drive Noisy Diagnostic Procedure .............................................................................................. 36 Final Drive Leaking Oil Diagnostic Procedure ..................................................................................... 37 Cross-Axle Differential Lock (CDL) Does Not Work ............................................................................. 38 Inter-Axle Differential Lock (IDL) Does Not Work ................................................................................ 40 Differential Assembly Noisy and/or Overheating Diagnostic Procedure ............................................. 41 Service Brake Excessive Wear Diagnostic Procedure ......................................................................... 43 Poor or No Service Brake Diagnostic Procedure ................................................................................. 45 Time Between Service Brake Accumulator Charging Cycles Too Short Diagnostic Procedure ............ 46 Service Brake Overheats Diagnostic Procedure ................................................................................. 47 Axle Oil Leaking Diagnostic Procedure ............................................................................................... 48 Service Brake Noise and Vibration Diagnostic Procedure ................................................................... 48 Service Brakes Do Not Fully Release Diagnostic Procedure ............................................................... 50 Park Brake Does Not Release Diagnostic Procedure ........................................................................... 51 Park Brake Will Not Hold Diagnostic Procedure .................................................................................. 53 Machine Will Not Move Diagnostic Procedure ..................................................................................... 55 Transmission Will Not Shift to Forward or Reverse Diagnostic Procedure .......................................... 57 Machine Creeps in Neutral Diagnostic Procedure ............................................................................... 58 Engine Speed Too High During Torque Converter Stall Diagnostic Procedure .................................... 59 Engine Speed Too Low During Torque Converter Stall Diagnostic Procedure ..................................... 61 Excessive Clutch Slippage and Chatter Diagnostic Procedure ............................................................ 63 Oil Comes Out of Transmission Oil Fill Tube Diagnostic Procedure ..................................................... 63 Buzzing Noise from Transmission Diagnostic Procedure .................................................................... 65 Transmission Overheating in All Gears Diagnostic Procedure ............................................................ 66 Transmission Not Shifting Properly (Rough Shifts, Shifting at Too-Low or Too-High Speed) Diagnostic Procedure .................................................................................................................................... 68 Transmission Will Not Make a Specific Shift Diagnostic Procedure ..................................................... 70 Transmission Retarder Does Not Function Diagnostic Procedure ....................................................... 71 Transmission Retarder Weak Diagnostic Procedure ........................................................................... 73 Retarder Stays On When Not Requested Diagnostic Procedure ......................................................... 75 Transmission Retarder Too Aggressive Diagnostic Procedure ............................................................ 77 Group 25 - Tests ..................................................................................................................................... 78 Transmission Warmup Procedure ....................................................................................................... 78 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
JT02156A Digital Pressure/Temperature Analyzer Kit Installation ...................................................... 80 Transmission Pressure Test ................................................................................................................ 81 Transmission Clutch Drag Test ........................................................................................................... 85 Transmission Pump Flow Test ............................................................................................................ 87 Transmission Oil Cooler Restriction Test ............................................................................................ 89 Transmission Oil Cooler Thermal Bypass Valve Temperature Test ..................................................... 91 Transmission Oil Cooler Thermal Bypass Valve Pressure Test ............................................................ 93 Torque Converter—Inlet Pressure Test ............................................................................................... 95 Torque Converter—Outlet Flow Test and Relief Pressure Test ........................................................... 97 Torque Converter Stall Test .............................................................................................................. 101 Torque Converter Stator Tests ......................................................................................................... 103 Torque Converter Lockup Test ......................................................................................................... 104 Electronic Clutch Calibration ............................................................................................................ 106 Service Brake Accumulator Pressure Regulator Valve Test and Adjustment .................................... 108 Service Brake Accumulator Charge Valve Test and Adjustment ....................................................... 111 Service Brake Low Pressure Switch and Service Brake Accumulator Charge Test ........................... 114 Front and Rear Service Brake Accumulators Pressure Test and Charge Procedure .......................... 117 Service Brake Valve Test .................................................................................................................. 120 Electronic Brake Valve (EBV) Test .................................................................................................... 123 Axle Cooling Pump Pressure Test and Flow Test .............................................................................. 125 Park Brake Test ................................................................................................................................ 128 Park Brake Pressure Test .................................................................................................................. 129 Park Brake Pad Thickness Check ...................................................................................................... 130 Park Brake Adjustment ..................................................................................................................... 131 Strut Accumulator Pressure Test and Charge Procedure .................................................................. 132 Cross-Axle Differential Lock (CDL) Pressure Test and Adjustment ................................................... 136 Inter-Axle Differential Lock (IDL) Pressure Test ................................................................................ 141 Checking Controlled Traction Clutch (Differential Lock) Condition ................................................... 142 Middle and Rear Axle Oil Sampling Procedure .................................................................................. 143
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TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Group 05 - Theory of Operation Transmission Control System Controllers, sensors, switches, valves, and solenoids contribute to the control of the transmission. The solenoids, switches and valves perform mechanical functions; the sensors provide data to the transmission control unit (TCU). The TCU communicates with other controllers via the controller area network (CAN) to control the transmission based on machine and operator input. The TCU processes this information and signals the transmission control valve to actuate specific solenoid valves. Solenoid valves allow pressure to flow to specific clutch packs to provide transmission shifts to match engine speed and operating conditions. Shifts are measured and stored by the TCU; optimum shift rates are adapted for operating conditions. The TCU will refine shifts at a slower rate as conditions remain constant. Transmission sensors provide input to the TCU to protect the transmission. For more information regarding transmission control see: The charge pump draws oil from the sump through a maintenance free suction screen and supplies oil to the main system and pilot pressure valves via the remote mounted filters. The eight clutches are directly controlled modulation valves. The modulation valves consist of the electro-hydraulic pressure control valve (pre-control unit), the downstream valve (amplifier), and the governor spring. Both valve housings have a pressure reducing valve to generate pilot pressure for actuating the modulation valves and to facilitate hydraulic crossover of the engaging/disengaging clutches. The system pressure valve limits maximum clutch pressure and releases full flow to the retarder, converter, and lubrication circuits. The inlet side torque converter safety valve protects against high internal converter pressures by first opening to the lubrication circuit and then to the sump. The outlet side torque converter back pressure valve, which ensures that the converter is always completely filled with oil, first opens to the lubrication circuit before opening to the sump. The cooler redirection valve directs the oil from the converter through the cooler and on to the lubrication circuit. See Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-05.) See Transmission System Schematic . (Group 9020-05.) See Shifting the Transmission . (Operator′s Manual.)
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Section 9020 page 1
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Transmission Cross Sectional Diagram
Transmission Cross Sectional Diagram (Side View) LEGEND: 1 2 3 4 <- Go to Section TOC
Oil Pickup Front Output Shaft Clutch E Oil Pump Section 9020 page 2
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
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Group 05: Theory of Operation
Oil Pump Drive Gear Input Shaft Torque Converter Lockup Clutch Torque Converter Housing Torque Converter Turbine Torque Converter Stator Torque Converter Pump Transmission Retarder Valve Block Transmission Retarder Stator Transmission Retarder Rotor Transmission Control Unit (TCU) Transmission Control Valve Body Clutch V Clutch B Clutch D Clutch F Clutch G (inter-axle differential lock (IDL)) Rear Output Shaft
Section 9020 page 3
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Transmission Cross Sectional Diagram (Top View) LEGEND: 17 18 23 24 25 <- Go to Section TOC
Clutch V Clutch B Clutch C Clutch A Clutch R Section 9020 page 4
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Transmission System Schematic
Transmission System Schematic
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Section 9020 page 5
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 600 602 603 604 Y60 Y61 Y62 Y63 Y64 Y65 Y66 Y67 Y68 <- Go to Section TOC
Group 05: Theory of Operation
Transmission Control Valve Block Housing Retarder Control Valve Block Transmission Control Valve Block Reducing Valve (2 used) Transmission Filter (2 used) Transmission Pump Transmission Clutch G (inter-axle differential lock (IDL)) Transmission Clutch A Transmission Clutch B Transmission Clutch C Transmission Clutch D Transmission Clutch F (planetary hi/lo) Transmission Clutch R Transmission Clutch V Transmission Clutch E Torque Converter Lockup Clutch Torque Converter Transmission Cooler Transmission Retarder Modulation Valve Retarder Regulation Valve Transmission Cooler Redirection Actuation Valve Torque Converter Safety Valve Torque Converter Back Pressure Valve Transmission Cooler Redirection Valve Modulation Valve A Modulation Valve B Modulation Valve C Modulation Valve D Modulation Valve F Modulation Valve R Modulation Valve V Modulation Valve E Torque Converter Lockup Clutch Modulation Valve Transmission Retarder Modulation Valve Measuring Port Clutch A Measuring Port Clutch B Measuring Port Clutch C Measuring Port Clutch D Measuring Port Clutch F Measuring Port Clutch R Measuring Port Clutch V Measuring Port Clutch E Measuring Port Torque Converter Lockup Clutch Measuring Port From Transmission Cooler Measuring Port to Transmission Cooler Measuring Port Lubrication Measuring Port From Bypass Measuring Port Pressure to Converter Measuring Port from Transmission Filter Measuring Port to Transmission Filter Measuring Port System Pressure Measuring Port Clutch G High Pressure Oil Low Pressure Oil Lubrication Oil Return/Pressure Free Oil Transmission Clutch A Solenoid Transmission Clutch B Solenoid Transmission Clutch C Solenoid Transmission Clutch D Solenoid Transmission Clutch E Solenoid Transmission Clutch F (planetary hi/lo) Solenoid Transmission Clutch R Solenoid Transmission Clutch V Solenoid Torque Converter Lockup Solenoid Section 9020 page 6
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Y69 Y70
Group 05: Theory of Operation
Transmission Retarder Solenoid Transmission Clutch G Solenoid
The ZF ErgoPower L II is a multi-speed transmission with integrated transfer box and front-mounted hydrodynamic torque converter. The torque converter is a wear-free, continuously variable start-up device. A retarder (hydrodynamic brake) is installed between the torque converter and the transmission which provides a good braking effect in all gears. The transmission consists of a countershaft with four gears and a two-step planetary drive. This arrangement is beneficial to high efficiency as it ensures a low internal speed. The transmission shifts by hydraulically actuating multi-disk clutches. A compression spring moves the piston back, releasing the multi-disk package. All gears are in constant mesh and supported by rolling elements. For more information on transmission theory see the following: Torque Converter Operation . (Group 9020-05.) Transmission Clutch Engagement . (Group 9020-05.) Transmission Retarder Operation . (Group 9020-05.)
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Section 9020 page 7
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Torque Converter Operation
Torque Converter and Lockup Clutch LEGEND: 1 Impeller 2 Turbine Wheel 3 Stator 4 Lockup Clutch Rotating the impeller (1) sends pressure oil into motion. Oil flow meets the turbine wheel (2) and is reversed. The stator (3) is connected to the transmission housing by a free wheel. The stator’s function is to reverse the oil streaming out of the turbine once more and to deliver it to the impeller wheel in the suitable input flow direction. Due to this reversion, the stator receives a reaction torque, which is supported by the locked free wheel at the housing. Thus the turbine torque is increased. The stator torque always equals the difference between turbine and pump momentum. The turbine torque to pump torque relation is called conversion. The higher the speed difference between pump and turbine wheel, the larger the conversion. The maximum conversion is reached when the turbine wheel is stationary (stall speed). With locked lockup clutch (4), the slip between pump wheel and turbine wheel (and consequently the hydraulic loss in the converter) is zero. The lockup clutch is shifted automatically, depending on the turbine speed. Actuation pressure is provided from a pressure control valve to the actuation piston, which compresses the multi-disk unit. For more information on torque converter operation see Transmission System Schematic . (Group 9020-05.)
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Section 9020 page 8
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Transmission Clutch Engagement
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Section 9020 page 9
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Transmission Clutch Engagement Main Schematic
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Section 9020 page 10
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Section 9020 - POWER TRAIN
LEGEND: 2 3 4 5 6 7 8 9 10 11 12 13 14 15 26 27 28 29 30 31 32 33 36 37 38 39 40 41 42 43 44 600 602 603 604 700 701 702 703 704 Y60 Y61 Y62 Y63 Y64 Y65 Y66 Y67 Y68 Y69 Y70
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Group 05: Theory of Operation
Retarder Control Valve Block Transmission Control Valve Block Reducing Valve (2 used) Transmission Filter (2 used) Transmission Pump Transmission Clutch G (Inter-Axle Differential Lock (IDL)) Transmission Clutch A Transmission Clutch B Transmission Clutch C Transmission Clutch D Transmission Clutch F (Planetary Hi/Lo) Transmission Clutch R Transmission Clutch V Transmission Clutch E Modulation Valve A Modulation Valve B Modulation Valve C Modulation Valve D Modulation Valve F Modulation Valve R Modulation Valve V Modulation Valve E Measuring Port Clutch A Measuring Port Clutch B Measuring Port Clutch C Measuring Port Clutch D Measuring Port Clutch F Measuring Port Clutch R Measuring Port Clutch V Measuring Port Clutch E Measuring Port Clutch G High Pressure Oil Low Pressure Oil Lubrication Oil Return/Pressure Free Oil Lubrication Oil to Sump To Modulation Valve To Retarder Regulation Valve To Transmission Cooler Redirection Valve To Torque Converter Lockup Clutch Transmission Clutch A Solenoid Transmission Clutch B Solenoid Transmission Clutch C Solenoid Transmission Clutch D Solenoid Transmission Clutch E Solenoid Transmission Clutch F (Planetary Hi/Lo) Solenoid Transmission Clutch R Solenoid Transmission Clutch V Solenoid Torque Converter Lockup Solenoid Transmission Retarder Solenoid Transmission Clutch G Solenoid
Section 9020 page 11
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Section 9020 - POWER TRAIN
Group 05: Theory of Operation
First Gear Forward Engaged
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Section 9020 page 12
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Section 9020 - POWER TRAIN
LEGEND: 2 3 4 5 6 7 8 9 10 11 12 13 14 15 26 27 28 29 30 31 32 33 36 37 38 39 40 41 42 43 44 600 602 603 604 700 701 702 703 704 Y60 Y61 Y62 Y63 Y64 Y65 Y66 Y67 Y68 Y69 Y70
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Group 05: Theory of Operation
Retarder Control Valve Block Transmission Control Valve Block Reducing Valve (2 used) Transmission Filter (2 used) Transmission Pump Transmission Clutch G Transmission Clutch A Transmission Clutch B Transmission Clutch C Transmission Clutch D Transmission Clutch F (Planetary Hi/Lo) Transmission Clutch R Transmission Clutch V Transmission Clutch E Modulation Valve A Modulation Valve B Modulation Valve C Modulation Valve D Modulation Valve F Modulation Valve R Modulation Valve V Modulation Valve E Measuring Port Clutch A Measuring Port Clutch B Measuring Port Clutch C Measuring Port Clutch D Measuring Port Clutch F Measuring Port Clutch R Measuring Port Clutch V Measuring Port Clutch E Measuring Port Clutch G High Pressure Oil Low Pressure Oil Lubrication Oil Return/Pressure Free Oil Lubrication Oil to Sump To Modulation Valve To Retarder Regulation Valve To Transmission Cooler Redirection Valve To Torque Converter Lockup Clutch Transmission Clutch A Solenoid Transmission Clutch B Solenoid Transmission Clutch C Solenoid Transmission Clutch D Solenoid Transmission Clutch E Solenoid Transmission Clutch F (Planetary Hi/Lo) Solenoid Transmission Clutch R Solenoid Transmission Clutch V Solenoid Torque Converter Lockup Solenoid Transmission Retarder Solenoid Transmission Clutch G Solenoid
Section 9020 page 13
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Section 9020 - POWER TRAIN
Group 05: Theory of Operation
First Gear Reverse Engaged
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Section 9020 page 14
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Section 9020 - POWER TRAIN
LEGEND: 2 3 4 5 6 7 8 9 10 11 12 13 14 15 26 27 28 29 30 31 32 33 36 37 38 39 40 41 42 43 44 600 602 603 604 700 701 702 703 704 Y60 Y61 Y62 Y63 Y64 Y65 Y66 Y67 Y68 Y69 Y70
Group 05: Theory of Operation
Retarder Control Valve Block Transmission Control Valve Block Reducing Valve (2 used) Transmission Filter (2 used) Transmission Pump Transmission Clutch G Transmission Clutch A Transmission Clutch B Transmission Clutch C Transmission Clutch D Transmission Clutch F (Planetary Hi/Lo) Transmission Clutch R Transmission Clutch V Transmission Clutch E Modulation Valve A Modulation Valve B Modulation Valve C Modulation Valve D Modulation Valve F Modulation Valve R Modulation Valve V Modulation Valve E Measuring Port Clutch A Measuring Port Clutch B Measuring Port Clutch C Measuring Port Clutch D Measuring Port Clutch F Measuring Port Clutch R Measuring Port Clutch V Measuring Port Clutch E Measuring Port Clutch G High Pressure Oil Low Pressure Oil Lubrication Oil Return/Pressure Free Oil Lubrication Oil to Sump To Modulation Valve To Retarder Regulation Valve To Transmission Cooler Redirection Valve To Torque Converter Lockup Clutch Transmission Clutch A Solenoid Transmission Clutch B Solenoid Transmission Clutch C Solenoid Transmission Clutch D Solenoid Transmission Clutch E Solenoid Transmission Clutch F (Planetary Hi/Lo) Solenoid Transmission Clutch R Solenoid Transmission Clutch V Solenoid Torque Converter Lockup Solenoid Transmission Retarder Solenoid Transmission Clutch G Solenoid
The transmission control valve regulates the hydraulic circuits of the transmission. Transmission clutch solenoids located in the transmission control valve block receive electrical signals from the transmission control unit (TCU). When energized the transmission clutch solenoids shift and direct oil to the modulation valves. When the modulation valves are shifted, oil fills the respective clutch pack. Three clutch packs must be engaged in order for the machine to move. First forward gear is achieved by energizing transmission clutch solenoids (Y60, Y65, and Y67). Low pressure oil will shift modulation valves (26, 30, and 32), shifting the modulation valves delivers system high pressure oil to fill transmission clutches (8, 12, 14). High pressure oil is reduced through an orifice and present on the back side of the modulation valves. Once transmission clutch solenoids are deenergized they are shifted to their static position by springs. High pressure oil present on the back side of the modulation valve will shift the modulation valve to it’s static position, de-energizing the respective transmission clutch. For more information on transmission clutch engagement, see Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-05.)
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Section 9020 page 15
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Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Transmission Retarder Operation
Retarder Cross Section LEGEND: 1 2 3 4 5
Oil Feed Flange Stator Shaft Control Device Stator Rotor
The retarder consists of rotor (5), stator (4) and control device (3). The rotor (the rotating part of the retarder) is driven by the stator shaft (2). The stator (shaft) is connected to the transmission housing. Oil is introduced at the oil feed flange (1). Due to the rotation and the blade design of the rotor, the oil is reversed into the stator and from there returns to the rotor. The retarder is controlled by onboard electronics. The braking process itself is induced by a foot-operated control. The control unit sends a continuously variable signal to the electronics, which actuate the corresponding control valve and set the requested brake power in a continuously variable manner. The possible retarder actuating pressure is between 2.5 and 15 bar.
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Section 9020 page 16
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Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Transmission Retarder Operation LEGEND: 1 2 4 5 6 18 <- Go to Section TOC
Transmission Control Valve Housing Retarder Control Valve Block Reducing Valve Transmission Filter (2 used) Transmission Pump Transmission Cooler Section 9020 page 17
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Section 9020 - POWER TRAIN
19 20 21 22 25 600 602 603 604 700 701 702 703 704 Y69
Group 05: Theory of Operation
Transmission Retarder Modulation Valve Retarder Regulation Valve Transmission Cooler Redirection Actuation Valve Transmission Cooler Redirection Valve High Pressure Oil Low Pressure Oil Lubrication Oil Return/Pressure Free Oil System High Pressure Retarder Control Valve Block Low Pressure Low Pressure to Torque Converter Return Oil from Torque Converter Safety Valve Return Oil from Torque Converter Back Pressure Valve Transmission Retarder Solenoid
The transmission control valve housing is an integral part of the transmission control and consists of a modulation valve (20), the retarder regulation valve (21), the transmission cooler redirection valve (25), and its actuation valve (22). The retarder regulation valve (pressurized) releases the corresponding oil flow into the retarder circuit. Reversing the oil in the rotor blades delays the rotation movement of the rotor and the speed of the vehicle. This energy is transformed into heat energy by fluid friction and is released through an oil cooler. If the clutch is actuated during retarder operation, the brake torque is decreased, which preserves the clutch. For more information on the transmission retarder, see the following: See Transmission Control Unit (TCU) and Retarder Circuits Theory of Operation . (Group 9015-05.) See Transmission System Schematic . (Group 9020-05.)
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Section 9020 page 18
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Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Transmission Inter-Axle Differential Lock (IDL) Operation
Inter-Axle Differential Lock (IDL) LEGEND: 1 2 3 7 8 9 10 11 12 13 14 15 16 600
Transmission Control Valve Block Housing Retarder Control Valve Block Transmission Control Valve Block Transmission Clutch G (inter-axle differential lock (IDL)) Transmission Clutch A Transmission Clutch B Transmission Clutch C Transmission Clutch D Transmission Clutch F (planetary hi/lo) Transmission Clutch R Transmission Clutch V Transmission Clutch E Differential Lock Actuation Valve High Pressure Oil
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Section 9020 page 19
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Section 9020 - POWER TRAIN
602 604 700 701 A5 Y67 Y70
Group 05: Theory of Operation
Low Pressure Oil Return/Pressure Free Oil System High Pressure Manifold Low Pressure Transmission Control Unit (TCU) Transmission Clutch V Solenoid Transmission Clutch G (inter-axle differential lock (IDL)) solenoid
IMPORTANT: To prevent machine damage, engage differential locks only when slippery conditions exist. Damage to the differentials and unnecessary wear on the driveline and tires can be caused if operated on tarred or graded surfaces. Transmission clutch G inter-axle differential lock (7) is integrated into the output of the transmission. The planetary type interaxle differential proportions torque between the front and rear axles while also compensating for speed differences. The differential includes a multi-disk lockup clutch for a rigid connection between the front and rear axles. When this lock is engaged, the torque between front and rear drive shafts are split 50/50. Hydraulic system high pressure (700) is present at transmission clutch G solenoid (Y70). When transmission clutch G solenoid (Y70) is energized, this shift allows system pressure to activate transmission clutch G inter-axle differential lock (7). The function is activated from the SSM. The SSM will broadcast the switch state to the CCU, and the CCU will evaluate vehicle parameters to decide if it should send the message to the TCU (A5). If parameters are met, transmission clutch G solenoid (Y70) will activate to engage the IDL. For more information on the transmission inter-axle differential lock (IDL) operation, see Differential Lock Circuits Theory of Operation . (Group 9015-05.)
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Section 9020 page 20
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Cross-Axle Differential Lock (CDL) Operation
Cross-Axle Differential Lock (CDL) Operation
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Section 9020 page 21
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Section 9020 - POWER TRAIN
LEGEND: 24 25 31 32 33 34 35 36 37 38 39 40 41 42 43 600 604 701 702 703 704 705 711 712 715 B55 B58 B59 B60 B61 B62 B63 B64 B65 B67 B68 B69 Y9 Y52 Y53 Y54 Y55 Y56 Y57
Group 05: Theory of Operation
Front Axle Coolant Pump Left Side Fan Pump Front Axle Cooling Manifold Front Axle Oil Cooler Differential Lock (3 used) Service Brake Piston (4 used) Front Axle Axle Cooling Hydraulic Motor Middle Axle Cooling Pump Rear Axle Cooling Pump Middle Axle Cooling Manifold Middle Axle Oil Cooler Middle Axle Rear Axle Cooling Manifold Rear Axle High-Pressure Oil Return Oil From Brake Valve From Brake Valve From Hydraulic System Manifold Port BC From Hydraulic Reservoir To Hydraulic Reservoir To Hydraulic Return Manifold To Hydraulic Reservoir To Left and Right Fan Motors Rear Axle Pressure Sensor Front Axle Differential Lock Pressure Sensor Middle Axle Differential Lock Pressure Sensor Rear Axle Differential Lock Pressure Sensor Front Axle Temperature Sensor Middle Axle Temperature Sensor Rear Axle Temperature Sensor Front Axle Pressure Sensor Middle Axle Pressure Sensor Front Axle Filter Restriction Switch Middle Axle Filter Restriction Switch Rear Axle Filter Restriction Switch Left Side Fan Speed Solenoid Front Axle Differential Lock Apply Solenoid Middle Axle Differential Lock Apply Solenoid Rear Axle Differential Lock Apply Solenoid Front Axle Differential Lock Pressure Regulating Solenoid Middle Axle Differential Lock Pressure Regulating Solenoid Rear Axle Differential Lock Pressure Regulating Solenoid
High-pressure oil is present at the axle cooling manifolds (31, 39 and 42) when solenoids (Y52, Y53 and Y54) are energized, high-pressure oil is delivered to the differential lock clutch piston within the axle. For more information on the differential lock see the following: See Teammate V 1500 Series Axle Dif-Lok Differential Operation . (CTM115319.) See Differential Lock Circuits Theory of Operation . (Group 9015-05.) See Using Differential Lock . (Operator’s Manual.)
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Section 9020 page 22
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Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Service Brake System Operation
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Section 9020 page 23
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Service Brake System Operation (S.N. —668586)
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Section 9020 page 24
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LEGEND: 14 15 18 19 25 26 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 600 604 609 614 704 705 706 711 712 715 716 719 723 724 B12 B13 B35 B55 B58 B59 B60 B61 B62 B63 B64 B65 B67 B68 B69 Y2 Y8 Y9 Y52 Y53 Y54 Y55 Y56 Y57
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Group 05: Theory of Operation
Front Axle Brake Accumulator (2 used) Middle Axle Brake Accumulator (2 used) Electronic Brake Valve Brake Valve Front Axle Coolant Pump Left Side Fan Pump Front Axle Cooling Manifold Front Axle Oil Cooler Differential Lock (3 used) Service Brake Piston (4 used) Front Axle Axle Cooling Hydraulic Motor Middle Axle Cooling Pump Rear Axle Cooling Pump Middle Axle Cooling Manifold Middle Axle Oil Cooler Middle Axle Rear Axle Cooling Manifold Rear Axle Accumulator Charge Valve Accumulator Charge Orifice Priority Valve Signal Shuttle Valve Accumulator Pressure Reducing Valve Accumulator Orifice Accumulator Charge Check Valve Accumulator Shuttle Valve Front Axle Pressure Reducing Valve High-Pressure Oil Return Oil Pilot Oil Load Sense Oil From Hydraulic Reservoir To Hydraulic Reservoir To Park Brake Manifold To Hydraulic Return Manifold To Hydraulic Reservoir To Secondary Steering Pump From Secondary Steering Pump From Main Hydraulic Pump To Hydraulic Reservoir To Left Side Fan Motor Main Hydraulic Pressure Sensor Secondary Steering Pressure Sensor Brake Accumulator Low-Pressure Switch Rear Axle Pressure Sensor Front Axle Differential Lock Pressure Sensor Middle Axle Differential Lock Pressure Sensor Rear Axle Differential Lock Pressure Sensor Front Axle Temperature Sensor Middle Axle Temperature Sensor Rear Axle Temperature Sensor Front Axle Pressure Sensor Middle Axle Pressure Sensor Front Axle Filter Restriction Switch Middle Axle Filter Restriction Switch Rear Axle Filter Restriction Switch Axle Cooling Cut-Off Solenoid Electronic Brake Valve Solenoid Left Side Fan Speed Solenoid Front Axle Differential Lock Apply Solenoid Middle Axle Differential Lock Apply Solenoid Rear Axle Differential Lock Apply Solenoid Front Axle Differential Lock Pressure Regulating Solenoid Middle Axle Differential Lock Pressure Regulating Solenoid Rear Axle Differential Lock Pressure Regulating Solenoid
Section 9020 page 25
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Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Service Brake System Operation (S.N. 668587— )
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Section 9020 page 26
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LEGEND: 14 15 18 19 25 26 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 600 604 609 614 704 705 706 711 712 715 716 719 723 724 B12 B13 B35 B55 B58 B59 B60 B61 B62 B63 B64 B65 B67 B68 B69 Y2 Y8 Y9 Y52 Y53 Y54 Y55 Y56 Y57
Group 05: Theory of Operation
Front Axle Brake Accumulator (2 used) Middle Axle Brake Accumulator (2 used) Electronic Brake Valve Brake Valve Front Axle Coolant Pump Left Side Fan Pump Front Axle Cooling Manifold Front Axle Oil Cooler Differential Lock (3 used) Service Brake Piston (4 used) Front Axle Axle Cooling Hydraulic Motor Middle Axle Cooling Pump Rear Axle Cooling Pump Middle Axle Cooling Manifold Middle Axle Oil Cooler Middle Axle Rear Axle Cooling Manifold Rear Axle Accumulator Charge Valve Accumulator Charge Orifice Priority Valve Signal Shuttle Valve Accumulator Pressure Reducing Valve Accumulator Orifice Accumulator Charge Check Valve Accumulator Shuttle Valve Front Axle Pressure Reducing Valve High-Pressure Oil Return Oil Pilot Oil Load Sense Oil From Hydraulic Reservoir To Hydraulic Reservoir To Park Brake Manifold To Hydraulic Return Manifold To Hydraulic Reservoir To Secondary Steering Pump From Secondary Steering Pump From Main Hydraulic Pump To Hydraulic Reservoir To Left Side Fan Motor Main Hydraulic Pressure Sensor Secondary Steering Pressure Sensor Brake Accumulator Low-Pressure Switch Rear Axle Pressure Sensor Front Axle Differential Lock Pressure Sensor Middle Axle Differential Lock Pressure Sensor Rear Axle Differential Lock Pressure Sensor Front Axle Temperature Sensor Middle Axle Temperature Sensor Rear Axle Temperature Sensor Front Axle Pressure Sensor Middle Axle Pressure Sensor Front Axle Filter Restriction Switch Middle Axle Filter Restriction Switch Rear Axle Filter Restriction Switch Axle Cooling Cut-Off Solenoid Electronic Brake Valve Solenoid Left Side Fan Speed Solenoid Front Axle Differential Lock Apply Solenoid Middle Axle Differential Lock Apply Solenoid Rear Axle Differential Lock Apply Solenoid Front Axle Differential Lock Pressure Regulating Solenoid Middle Axle Differential Lock Pressure Regulating Solenoid Rear Axle Differential Lock Pressure Regulating Solenoid
Charging Service Brake System— When operating the brake valve (19), charge oil pressure in the front service brake <- Go to Section TOC
Section 9020 page 27
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Section 9020 - POWER TRAIN
Group 05: Theory of Operation
accumulators (14) and middle service brake accumulators (15) decreases. The decrease of charge oil pressure in the service brake accumulators is sensed by the accumulator charge valve (45). When the accumulator charge oil pressure decreases below the lower pressure setting of the accumulator charge valve, the charge valve spring shifts the spool, blocking the flow of load sense oil to the return circuit. Charge oil continues to flow through the service brake accumulator charge orifice (46), increasing load sense pressure. The increasing load sense pressure shifts the priority valve signal shuttle valve (47), sending the load sense signal out of port LSO to the main hydraulic pump. From the main hydraulic pump, high-pressure oil flows through the accumulator pressure reducing valve (48), accumulator orifice (49), and accumulator charge check valve (50). As pressure increases, the front and rear service brake accumulators are charged by way of the accumulator shuttle valve (51). Pressure to the front and middle service brake accumulators (14 and 15) is limited by the accumulator pressure reducing valve. The accumulator orifice controls the rate of oil flow to charge all the service brake accumulators. When service brake accumulator charge oil pressure increases to the upper pressure setting of the accumulator charge valve, the charge valve spool shifts to the open position, allowing load sense oil to flow to return, decreasing the load sense signal to the main hydraulic pump. The pump destrokes, decreasing supply oil flow to the service brake accumulators. Charged System— When all service brake accumulators are charged, charge oil in the service brake accumulators holds the accumulator charge check valve closed. The service brake accumulator charge oil keeps the accumulator charge valve open, allowing pump load sense oil to flow to return. The rear and front service brake accumulator circuits are separated by the accumulator shuttle valve, which holds charge oil in the middle and front service brake accumulators. The accumulator shuttle valve enables the circuits to work independently of each other in the event of a malfunction in either circuit. The pressure setting of the accumulator charge valve and accumulator pressure reducing valve is critical to operation of the main hydraulic pump. If the pressure setting of the accumulator charge valve is higher than the accumulator pressure reducing valve, the load sense signal to the main hydraulic pump will remain high. The charge oil pressure from the service brake accumulators cannot open the charge valve allowing load sense oil to flow to return. The main hydraulic pump will remain swashed and not return to neutral state (residual) pressure until all functions are in neutral. Neutral Service Brake Valve— The service brake valve is a dual circuit, modulated valve. The function of the valve is to control the charge oil from the front and rear service brake accumulators to actuate the service brakes. The brake valve contains two separate circuits, each supplied by its own set of accumulators. The service brake valve supplies charge oil to the middle service brakes first and then the front service brakes. In neutral, charge oil is blocked by the service brake valve spools. Actuated Service Brake Valve— When service brakes are actuated, the charge oil in the service brake accumulators flows through the service brake valve to the brake pistons, applying the wet disk service brakes. The pressure applied at the pistons and the force applied to the service brake valve spring by the service brake pedal act on opposite ends of the spools in the service brake valve. The pressure to the pistons is proportional to the force applied to the service brake pedal (pressure to the pistons increases as the force on the brake pedal increases). The pressure on the end of the spools balances against the spring force modulating the pressure to the pistons. The service brake accumulators stored charge oil is reduced by the amount of oil it takes to move the pistons. Each application of the service brake pedal reduces the service brake accumulators stored charge oil until the service brake accumulator charge circuit is actuated by the accumulator charge valve. Electronic Brake Valve (EBV)— The service brake is primarily a hydraulically actuated system, controlled by the operator’s use of a foot pedal. An electronically controlled brake valve, connected in parallel with the foot brake, provides a secondary means of applying brake pressure. The actual braking force will be combined forces of both the foot brake and the electronic brake valve. The EBV can only act to increase braking effort, not to reduce it. The EBV contains an orifice to prevent brake noise and vibration. Service Brake Cooling System— An axle-specific/closed loop hydraulic system cools each service brake. The service brake is cooled with axle lube oil. The axle serves as its own hydraulic reservoir. A pick-up tube inside the differential housing picks up lube/cooling oil and circulates it through a filter and cooler. There are bypass check valves after each service brake pump that allows return oil back to the axle if coolers become plugged or if service brake cooling oil is cold due to low ambient temperatures. For more information on service brake operation, see Teammate V 1500 Series Axle Service Brake Operation . (CTM115319.)
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Section 9020 page 28
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Section 9020 - POWER TRAIN
Group 05: Theory of Operation
Park Brake Operation
Park Brake Components LEGEND: 1 2 3 4 5 6 7 8 B12 B15 B35 Y45 Y46 600 604 609 614
Hydraulic System Manifold Electronic Brake Supply Port EB Park Brake Manifold Park Brake Pressure Relief Valve Park Brake Release Piston Brake Pressure Regulator Supply From Secondary Steering Pump Port P2 Main Hydraulic Inlet Port P Main Hydraulic Pressure Sensor Park Brake Pressure Sensor Brake Accumulator Low Pressure Switch Park Brake Release solenoid 2 Park Brake Release solenoid 1 High-Pressure oil Return Oil Pilot Oil Load Sense Oil
The park brake is mechanically applied with spring pressure. Hydraulic pressure is used to operate an actuator that overcomes the mechanical pressure of the park brake spring to release the park brake. The park brake release piston (5) receives its oil from the main hydraulic pump at inlet port P (8) on the hydraulic system manifold (1). Load sense oil is created by brake pressure regulator (6) and is routed to the park brake manifold (3). Park Brake Engaged— When park brake is engaged, normally closed park brake release solenoid 1 (Y46) blocks the flow of oil to park brake release piston (5). Normally open park brake release solenoid 2 (Y45) allows oil to flow back to tank. With no hydraulic pressure acting on the park brake release piston (5), the park brake spring engages the park brake. Park Brake Disengaged— When park brake is disengaged, park brake release solenoid 1 (Y46) and park brake release solenoid 2 (Y45) is energized. Park brake release solenoid 1 (Y46) opens, allowing pilot oil from the hydraulic system manifold (1) to flow to the park brake release piston (5). Park brake release solenoid 2 (Y45) closes and blocks the flow of oil to tank. The hydraulic pressure at the park brake release piston overcomes the spring tension and releases the park brake. Park brake pressure relief valve (4) regulates the pressure to park brake release piston. For more information on the electrical components in the park brake circuit or for information on manually releasing the park brake, see the following: See Park Brake Circuit Theory of Operation . (Group 9015-05.) <- Go to Section TOC
Section 9020 page 29
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Group 05: Theory of Operation
See Mechanically Releasing Park Brake . (Operator’s Manual.)
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Section 9020 page 30
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Group 15: Diagnostic Information
Suspension System Operation
Suspension System Operation LEGEND: 27 28 29 30 31 600 604 606 614 708 709 710 Y38 Y39 Y40 Y41
Left Strut Accumulator Left Strut Active Suspension Manifold Right Strut Right Strut Accumulator High Pressure Oil Return Oil Trapped Oil Load Sense Oil From Hydraulic System Manifold Port AS To Hydraulic Return Manifold To LSP Shuttle Valve Right Strut Up Solenoid Right Strut Down Solenoid Left Strut Up Solenoid Left Strut Down Solenoid
The suspension control is a closed loop system. Ride height is based on midpoint stroke position of the strut cylinders. Stroke position is measured by ratio metric Hall-effect rotary sensors. Hydraulic system pressure oil is controlled by the strut up solenoids (Y38 and Y40). Energizing the strut up solenoids releases trapped oil and allows mechanical spools to shift, delivering high pressure oil through the strut up solenoids to the struts. Energizing the strut down solenoids (Y39 and Y41) allows hydraulic oil to bleed from the struts back to the hydraulic tank. For more information on the operation of the suspension, see Suspension Height Control Circuit Theory of Operation . (Group 9015-15.)
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Section 9020 page 31
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Group 15: Diagnostic Information
Group 15 - Diagnostic Information Transmission External Components
Transmission External Components LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Transmission Transmission Fill Tube Rear Output Shaft Transmission Drain Valve Dipstick Tube Block Transmission Filter Restriction Switch Transmission Filter (2 used) Transmission-to-Filter Housing Supply Hose Transmission Filter Housing Transmission Filter Housing-to-Transmission Bypass Hose Transmission Filter Housing-to-Transmission Return Hose Lifting Eye (3 used) Transmission-to-Transmission Oil Cooler Supply Hose Transmission Oil Cooler-to-Transmission Return Hose Thermal Bypass Valve Transmission Oil Cooler Transmission Control Unit (TCU) Transmission Valve Module Harness Transmission Valve Module Lube Pressure Test Port Breather Torque Converter Lockup Clutch Test Port Clutch V (forward) Test Port
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Section 9020 page 32
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24 25 26 27 28 29 30 31 32 33 34 35
Group 15: Diagnostic Information
System Pressure Test Port Clutch E Test Port Clutch G (inter-axle differential lock) Test Port Clutch C Test Port Brake (hi/lo planetary) F Test Port Clutch A Test Port Clutch R (reverse) Test Port Clutch B Test Port Clutch D Test Port Front Output Shaft Dipstick Input Shaft
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Section 9020 page 33
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Group 15: Diagnostic Information
Power Train Component Location
Power Train Component Location
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Section 9020 page 34
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LEGEND: 1 2 3 4 5 6 7
Group 15: Diagnostic Information
Front Axle Front Suspension Strut (2 used) Transmission Park Brake Middle Axle Walking Beam (2 used) Rear Axle
For more information on related components, see the following: Transmission External Components . (Group 9020-15.) Hydraulic System Component Location . (Group 9025-15.)
Service Brake Circuit Component Location For information on the service brake circuit, see Hydraulic System Component Location . (Group 9025-15.) Axle Breather Leaking 81
Axle Breather Leaking Diagnostic Procedure ( 1 ) Axle Breather Check
Action: Check axle oil level. See Check Axle Oil Levels . (Operator’s Manual.) Is axle oil level correct?
Result: YES:Checks complete. If oil level and type are correct and axle breather is still leaking, see Axle Troubleshoot Axle and Differential . (CTM115319.) NO:Adjust oil level. See Check Axle Oil Levels . (Operator’s Manual.)
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Section 9020 page 35
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Final Drive Overheating 81
Final Drive Overheating Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Axle Oil Level Check. ( 2 ) Axle Oil Level Check
Action: Check axle oil level. See Check Axle Oil Levels . (Operator’s Manual.) Is axle oil level correct?
Result: YES:Go to Final Drive Planetary Check. NO:Adjust oil level. See Check Axle Oil Levels . (Operator’s Manual.) ( 3 ) Final Drive Planetary Check
Action: Check final drive planetary for wear or damage. See Final Drive Assembly . (CTM115319.) Is final drive planetary worn or damaged?
Result: YES:Repair or replace final drive planetary as necessary. See Final Drive Assembly . (CTM115319.) NO:Checks complete. For additional information on troubleshooting the final drive, see Teammate V 1500 Series Axle Troubleshoot Axle and Differential . (CTM115319.) Final Drive Noisy 81
Final Drive Noisy Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). <- Go to Section TOC
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Group 15: Diagnostic Information
NO:Go to Axle Oil Level Check. ( 2 ) Axle Oil Level Check
Action: Check axle oil level. See Check Axle Oil Levels . (Operator’s Manual.) Is axle oil level correct?
Result: YES:Go to Final Drive Planetary Check. NO:Adjust oil level. See Check Axle Oil Levels . (Operator’s Manual.) ( 3 ) Final Drive Planetary Check
Action: Check final drive planetary for wear or damage. See Final Drive Assembly . (CTM115319.) Is final drive planetary worn or damaged?
Result: YES:Repair or replace final drive planetary as necessary. See Final Drive Assembly . (CTM115319.) NO:Checks complete. For additional information on troubleshooting the final drive, see Teammate V 1500 Series Axle Troubleshoot Axle and Differential . (CTM115319.) Final Drive Leaking Oil 81
Final Drive Leaking Oil Diagnostic Procedure ( 1 ) Axle Oil Level Check
Action: Check axle oil level. See Check Axle Oil Levels . (Operator’s Manual.) Is axle oil level correct?
Result: YES:Go to Final Drive Planetary Check. NO:Adjust axle oil level. See Check Axle Oil Levels . (Operator’s Manual.) ( 2 ) Final Drive Planetary Check
Action: Check final drive O-ring. See Outboard Planetary Assembly O-ring—Removal . (CTM115319.) Is final drive O-ring worn or damaged?
Result: YES:Repair or replace final drive planetary as necessary. See Final Drive Assembly List . (CTM115319.) NO:Checks complete. For additional information on troubleshooting the final drive, see Axle Troubleshoot Axle and Differential . (CTM115319.)
<- Go to Section TOC
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Group 15: Diagnostic Information
Cross-Axle Differential Lock (CDL) Does Not Work Cross-Axle Differential Lock (CDL) Does Not Work ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Axle Oil Level Check. ( 2 ) Axle Oil Level Check
Action: Check axle oil level. See Check Axle Oil Levels . (Operator’s Manual.) Is axle oil at correct level?
Result: YES:Go to Cross-Axle Differential Lock (CDL) Operating Conditions Check. NO:Adjust axle oil to correct level. See Check Axle Oil Levels . (Operator’s Manual.) ( 3 ) Cross-Axle Differential Lock (CDL) Operating Conditions Check
Action: Check to see if machine conditions and operating conditions are met, allowing the (CDL) to operate, see Using Differential Lock . (Operator’s Manual.) Are machine conditions and operating conditions satisfied, allowing the (CDL) to operate?
Result: YES:Go to Operate the Cross-Axle Differential Lock (CDL) Check. NO:Provide conditions which allow the cross-axle differential lock (CDL) to operate. ( 4 ) Operate the Cross-Axle Differential Lock (CDL) Check
Action: Attempt to engage the cross-axle differential lock (CDL). See Using Differential Lock . (Operator’s Manual.) Does the Cross-Axle Differential Lock (CDL) engage?
Result: YES:Checks Complete. NO:Go to Cross-Axle Differential Lock (CDL) Electrical Check. ( 5 ) Cross-Axle Differential Lock (CDL) Electrical Check
Action: Check electrical components and wire harnesses related to the cross-axle differential lock (CDL). See Differential Lock Circuits Theory of Operation . (Group 9015-15.) <- Go to Section TOC
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Group 15: Diagnostic Information
Is the electrical system preventing the cross-axle differential lock (CDL) from operating?
Result: YES:Repair electrical malfunction. NO:Go to Cross-Axle Differential Lock (CDL) Hydraulic Pressure Check. ( 6 ) Cross-Axle Differential Lock (CDL) Hydraulic Pressure Check
Action: Check hydraulic pressure circuit. See Differential Lock Circuits Theory of Operation . (Group 9020-20.) Is hydraulic pressure to specification?
Result: YES:Diagnose and repair cross-axle differential lock (CDL). See Teammate V 1500 Series Axle Troubleshoot Axle and Differential . (CTM115319.) NO:Repair or replace (CDL) hydraulic lines. See Hydraulic System Component Location . (Group 9025-15.)
<- Go to Section TOC
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Group 15: Diagnostic Information
Inter-Axle Differential Lock (IDL) Does Not Work Inter-Axle Differential Lock (IDL) Does Not Work ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Transmission Oil Level Check. ( 2 ) Transmission Oil Level Check
Action: Check transmission oil level. See Check Transmission Oil Level . (Operator’s Manual.) Is transmission oil level correct?
Result: YES:Go to Inter-Axle Differential Lock (IDL) Operating Conditions Check. NO:Adjust transmission oil level. See Check Transmission Oil Level . (Operator’s Manual.) ( 3 ) Inter-Axle Differential Lock (IDL) Operating Conditions Check
Action: Check to see if machine conditions and operating conditions are met, allowing the (IDL) to operate, see Using Differential Lock . (Operator’s Manual.) Are machine conditions and operating conditions satisfied, allowing the (IDL) to operate?
Result: YES:Go to Operate the Inter-Axle Differential Lock (IDL) Check. NO:Provide conditions which allow the inter-axle differential lock (CDL) to operate. ( 4 ) Operate the Inter-Axle Differential Lock (IDL) Check
Action: Attempt to engage the inter-axle differential lock (IDL). See Using Differential Lock . (Operator’s Manual.) Does the inter-axle differential lock (IDL) engage?
Result: YES:Checks complete. NO:Go to Inter-Axle Differential Lock (IDL) Electrical Check. ( 5 ) Inter-Axle Differential Lock (IDL) Electrical Check
Action: Check electrical components and wire harnesses related to the inter-axle differential lock (IDL). See Differential Lock Circuits Theory of Operation . (Group 9015-15.) <- Go to Section TOC
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Is the electrical system preventing the inter-axle differential lock (IDL) from operating?
Result: YES:Repair electrical malfunction. NO:Go to Inter-Axle Differential Lock (IDL) Hydraulic Pressure Check. ( 6 ) Inter-Axle Differential Lock (IDL) Hydraulic Pressure Check
Action: Check inter-axle differential (IDL) hydraulic pressure circuit. See Transmission Pressure Test . (Group 9020-25.) Is inter-axle differential lock (IDL) hydraulic pressure to specification?
Result: YES:Inter-axle differential lock (IDL) hydraulic pressure is to specification but the (IDL) will not engage. Repair transmission as required. See Transmission Disassemble . (Group 0350.) NO:Inter-axle differential lock (IDL) hydraulic pressure is not to specification. Diagnose and repair the transmission control valve and/or the transmission as required. See Transmission Pressure Test (Group 9020-25.) and see Transmission Disassemble . (Group 0350.) If the transmission control valve is in question see Transmission Control Valve Disassemble and Assemble . (Group 0350.) Differential Assembly Noisy and/or Overheating 81
Differential Assembly Noisy and/or Overheating Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Axle Oil Level Check. ( 2 ) Axle Oil Level Check
Action: Check axle oil level. See Check Axle Oil Levels . (Operator’s Manual.) Are axle oil type and level correct?
Result: YES:Go to Differential Check. NO:Adjust oil level. See Check Axle Oil Levels . (Operator’s Manual.) ( 3 ) Differential Check
Action: Check differential for wear or damage. See Teammate V 1500 Series Axle Troubleshoot Axle and Differential . (CTM115319.) Is differential assembly worn or damaged?
<- Go to Section TOC
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Group 15: Diagnostic Information
Result: YES:Repair or replace differential assembly as necessary. See Differential Gear Case Assembly—Assembly . (CTM115319.) NO:Checks complete.
<- Go to Section TOC
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Service Brake Excessive Wear 81
Service Brake Excessive Wear Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Service Brake Pedal Check. ( 2 ) Service Brake Pedal Check
Action: Check service brake pedal for obstructions. Is debris preventing service brake pedal from returning fully?
Result: YES:Remove debris from around service brake pedal. NO:Go to Service Brake Valve Check. ( 3 ) Service Brake Valve Check
Action: Check service brake valve function. See Service Brake Valve Test . (Group 9025-25.) Does service brake valve function within specifications?
Result: YES:Go to Service Brake Check. NO:Replace service brake valve. See Brake Valve Remove and Install . (Group 9025-25.) ( 4 ) Service Brake Check
Action: Check service brake disks for warping or wear. See Multi-Disk Viton Brake Assembly—Removal . (CTM115319.) →NOTE: Only replace service brake discs if discs below recommended thickness. Are service brake disks warped or worn? →NOTE: Only replace service brake discs if discs below recommended thickness.
Result: YES:Replace service brake disks. See Multi-Disk Viton Brake Assembly—Teardown . (CTM115319.) <- Go to Section TOC
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Group 15: Diagnostic Information
NO:Checks complete.
<- Go to Section TOC
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Group 15: Diagnostic Information
Poor or No Service Brake 81
Poor or No Service Brake Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Service Brake Pedal Check. ( 2 ) Service Brake Pedal Check
Action: Check service brake pedal for obstructions around and under pedal. Check for full pedal stroke in both directions. Is service brake pedal clear of obstructions and allowing full stroke in both directions?
Result: YES:Go to Service Brake Pad Wear Check. NO:Remove obstruction. ( 3 ) Service Brake Wear Check
Action: Check service brake wear. See Service Brake Visual Inspection . (CTM115319.) Are service brake pads to specifications? →NOTE: Only replace service brake discs if discs below recommended thickness.
Result: YES:Go to Service Brake Line Blocked or Restricted Check. NO:Replace service brake pads. See Mutli-Disk Viton Brake Assembly—Removal . (CTM115319.) ( 4 ) Service Brake Line Blocked or Restricted Check
Action: Check service brake lines for blockage or restrictions. See Hydraulic System Component Location . (Group 9025-15.) Is service brake line blocked or restricted?
Result: YES:Repair or replace service brake lines as necessary. NO:Go to Service Brake Valve Check. ( 5 ) Service Brake Valve Check
<- Go to Section TOC
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Group 15: Diagnostic Information
Action: Check service brake valve operation. Perform Service Brake Valve Test . (Group 9020-25.) Is service brake valve operation to specification?
Result: YES:Go to Service Brake Accumulator Check. NO:Replace service brake valve. See Brake Valve Remove and Install ( 6 ) Service Brake Accumulator Check
Action: Check service brake accumulators. Perform Service Brake Accumulator Charge Valve Test and Adjustment and perform Service Brake Accumulator Pressure Reducing Valve Test and Adjustment . (Group 9020-25.) Is service brake accumulator pressure to specification?
Result: YES:Checks complete. NO:Adjust pressures or replace service brake accumulator. Perform Brake Accumulator Remove and Install . (Group 1060.) Time Between Service Brake Accumulator Charging Cycles Too Short 62
Time Between Service Brake Accumulator Charging Cycles Too Short Diagnostic Procedure ( 1 ) Service Brake Accumulator Check
Action: Check service brake accumulator charge pressure. See Service Brake Low Pressure Switch and Service Brake Accumulator Charge Test . (Group 9020-25.) Is service brake accumulator charge pressure to specification?
Result: YES:Check complete. NO:Adjust pressures or replace service brake accumulator. Perform Brake Accumulator Remove and Install . (Group 1060.)
<- Go to Section TOC
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Service Brake Overheats 81
Service Brake Overheats Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Axle Oil Level Check. ( 2 ) Axle Oil Level Check
Action: Check axle oil level. See Check Axle Oil Levels . (Operator’s Manual.) Is axle oil at correct level?
Result: YES:Go to Service Brake Pedal Check. NO:Adjust axle oil to correct level. See Check Axle Oil Levels . (Operator’s Manual.) ( 3 ) Service Brake Pedal Check
Action: Check service brake pedal for obstructions around and under pedal. Check for full pedal stroke in both directions. Is service brake pedal clear of obstructions and allowing full stroke in both directions?
Result: YES:Go to Service Brake Valve Check. NO:Remove obstruction. ( 4 ) Service Brake Valve Check
Action: Check service brake valve operation. Perform Service Brake Valve Test . (Group 9020-25.) Is service brake valve operation to specification?
Result: YES:Go to Service Brake Check. NO:Repair or replace service brake valve. See Brake Valve Remove and Install . (Group 1060.) ( 5 ) Service Brake Check
Action: Check service brake for dragging and overheating. See Teammate V 1500 Series Axle Troubleshoot Axle and Differential . (CTM115319.) <- Go to Section TOC
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Group 15: Diagnostic Information
Is the service brake operating properly? →NOTE: Only replace service brake discs if discs below recommended thickness.
Result: YES:Checks complete. NO:Diagnose and repair service brake as required. See Mutli-Disk Viton Brake Assembly—Removal . (CTM115319.) Axle Oil Leaking 81
Axle Oil Leaking Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Axle Oil Level Check. ( 2 ) Axle Oil Level Check
Action: Check axle oil level. See Check Axle Oil Levels . (Operator’s Manual.) Is axle oil at correct level?
Result: YES: See Teammate V 1500 Series Axle Troubleshoot Axle and Differential . (CTM115319.) NO:Adjust axle oil to correct level. See Check Axle Oil Levels . (Operator’s Manual.) Service Brake Noise and Vibration 81
Service Brake Noise and Vibration Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Axle Oil Level Check. ( 2 ) Axle Oil Level Check <- Go to Section TOC
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Group 15: Diagnostic Information
Action: Check axle oil level. See Check Axle Oil Levels . (Operator’s Manual.) Is axle oil at correct level?
Result: YES:Go to Electronic Brake Valve Orifice Check. NO:Adjust axle oil to correct level. See Check Axle Oil Levels . (Operator’s Manual.) ( 3 ) Electronic Brake Valve Orifice Check
Action: Check for orifice on electronic brake valve. For electronic brake valve location, see Hydraulic System Component Location . (Group 9025-15.) Is orifice installed on electronic brake valve?
Result: YES: See Teammate V 1500 Series Axle Troubleshoot Axle and Differential . (CTM115319.) NO:Install orifice on electronic brake valve.
<- Go to Section TOC
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Service Brakes Do Not Fully Release 81
Service Brakes Do Not Fully Release Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Service Brake Pedal Check. ( 2 ) Service Brake Pedal Check
Action: Check service brake pedal for obstructions around and under pedal. Check for full pedal stroke in both directions. Is service brake pedal clear of obstructions and allowing full stroke in both directions?
Result: YES:Go to Service Brake Valve Check. NO:Remove obstruction. ( 3 ) Service Brake Valve Check
Action: Check service brake valve operation. Perform Service Brake Valve Test . (Group 9020-25.) Is service brake valve operation to specification?
Result: YES:Go to Service Brake Check. NO:Replace service brake valve. See Brake Valve Remove and Install . (Group 1060.) ( 4 ) Service Brake Check
Action: Check service brake operation. See Teammate V 1500 Series Axle Service Brake Operation . (CTM115319.) Are the service brakes operating properly?
Result: YES:Checks complete. NO: See Teammate V 1500 Series Axle Troubleshoot Axle and Differential . (CTM115319.)
<- Go to Section TOC
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Group 15: Diagnostic Information
Park Brake Does Not Release 81
Park Brake Does Not Release Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Park Brake Pressure Check. ( 2 ) Park Brake Pressure Check
Action: Check park brake pressure. See Park Brake Pressure Test . (Group 9020-25.) Is park brake pressure at specification?
Result: YES:Go to Park Brake Actuator Check. NO:Diagnose hydraulic system as required. See Hydraulic System Schematic . (Group 9025-15.) NO:Diagnose electrical system as required. See Park Brake Circuit Theory of Operation . (Group 9015-15.) ( 3 ) Park Brake Actuator Check
Action: Check park brake actuator function. Is park brake actuator functioning properly?
Result: YES:Go to Park Brake Adjustment Check. NO:Replace actuator. See Park Brake Caliper Remove and Install . (Group 2262.) ( 4 ) Park Brake Adjustment Check
Action: Check park brake adjustment. See Park Brake Adjustment . (Group 9020-25.) Is park brake adjusted within specifications?
Result: YES:Go to Park Brake Caliper Check. NO:Adjust park brake. ( 5 ) Park Brake Caliper Check
Action: Check park brake caliper for wear or damage. <- Go to Section TOC
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Group 15: Diagnostic Information
Is park brake caliper worn or damaged?
Result: YES:Repair or replace park brake caliper as necessary. Perform Park Brake Caliper Remove and Install . (Group 1100.) NO:Go to Park Brake Disk Check. ( 6 ) Park Brake Disk Check
Action: Check park brake disk for wear or damage. Is park brake disk worn or damaged?
Result: YES:Replace park brake disk. Perform Park Brake Disk Remove and Install . (Group 1100.) NO:Checks complete.
<- Go to Section TOC
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Group 15: Diagnostic Information
Park Brake Will Not Hold 278
Park Brake Will Not Hold Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Park Brake Pressure Check. ( 2 ) Park Brake Pressure Check
Action: Check park brake pressure. Perform Park Brake Pressure Test . (9020-25.) Is pressure present at the park brake actuator?
Result: YES:Diagnose park brake control. See Park Brake Circuit Theory of Operation . (9015-15.) NO:Go to Park Brake Pads Check. ( 3 ) Park Brake Pads Check
Action: Check park brake pads for wear, damage, or oil. Are park brake pads worn, damaged, or oily?
Result: YES:Replace park brake pads. Perform Park Brake Pads Remove and Install . (Group 1100.) NO:Go to Park Brake Actuator Check. ( 4 ) Park Brake Actuator Check
Action: Check park brake actuator function. Is park brake actuator functioning properly?
Result: YES:Go to Park Brake Adjustment Check. NO:Replace actuator. See Park Brake Caliper Remove and Install . (Group 1100.) ( 5 ) Park Brake Adjustment Check
Action: Check park brake adjustment. Is the park brake adjusted within specifications? <- Go to Section TOC
Section 9020 page 53
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Result: YES:Go to Park Brake Caliper Check. NO:Adjust park brake. Perform Park Brake Adjustment . (Group 9020-25.) ( 6 ) Park Brake Caliper Check
Action: Check park brake caliper for wear or damage. Is park brake caliper worn or damaged?
Result: YES:Repair or replace park brake caliper as necessary. Perform Park Brake Caliper Remove and Install . (Group 1100.) NO:Go to Park Brake Disk Check. ( 7 ) Park Brake Disk Check
Action: Check park brake disk for wear or damage. Is park brake disk worn or damaged?
Result: YES:Replace park brake disk. Perform Park Brake Disk Remove and Install . (Group 1100.) NO:Checks complete.
<- Go to Section TOC
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Group 15: Diagnostic Information
Machine Will Not Move 81
Machine Will Not Move Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Torque Converter Check. ( 2 ) Torque Converter Check
Action: Check the torque converter. Perform the following tests: See Torque Converter—Inlet Pressure Test . (Group 9020-25.) See Torque Converter—Outlet Flow Test and Relief Pressure Test . (Group 9020-25.) Does the torque converter perform to specification?
Result: YES:Go to Service Brake Check NO:Replace the torque converter, see Torque Converter Remove and Install . (Group 0350.) ( 3 ) Service Brake Check
Action: Check the service brakes. Are the service brakes releasing fully?
Result: YES:Go to Park Brake Check. NO: See Service Brake Valve Test . (9025-25.) NO: See Teammate V 1500 Series Axle Troubleshoot Axle and Differential . (CTM115319.) ( 4 ) Park Brake Check
Action: Check park brake for release. Does park brake release as it should?
Result: YES:Go to Universal Joints and Drive Shafts Check. NO:Follow steps in Park Brake Does Not Release Diagnostic Procedure. See Park Brake Does Not Release . (Group 9020-15.) ( 5 ) Universal Joints and Drive Shafts Check
<- Go to Section TOC
Section 9020 page 55
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Action: Check universal joints and drive shafts. Are all universal joints and drive shafts connected?
Result: YES:Go to Alternate Gear Check. NO:Replace drive shaft(s) or universal joint(s). See Transmission-to-Front Axle Drive Shaft or Transmission-to-Oscillation Joint Drive Shaft Remove and Install . (Group 0225.) See Oscillation Joint Drive Shaft Remove and Install . (Group 0225.) See Park Brake-to-Middle Axle Drive Shaft Remove and Install . (Group 0225.) See Middle Axle-to-Rear Axle Drive Shaft Remove and Install . (Group 0225.) ( 6 ) Alternate Gear Check
Action: Check if shifting the transmission into an alternate gear will get the machine to move. See Shifting the Transmission . (Operator’s Manual.) Does the machine move using an alternate gear?
Result: YES:Diagnose the transmission control system. See Transmission Control System . (Group 9020-05.) YES:Diagnose the transmission. See Transmission Pressure Test . (Group 9020-25.) NO:Checks complete.
<- Go to Section TOC
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Transmission Will Not Shift to Forward or Reverse 81
Transmission Will Not Shift to Forward or Reverse Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Transmission Control System Check. ( 2 ) Transmission Control System Check
Action: Check the transmission control system. See Transmission Solenoids and Sensors Tests . (Group 9015-20.) When selecting a specific gear, do the appropriate transmission solenoids activate?
Result: YES:The appropriate solenoids activate, but the machine will not shift to forward or reverse. Go to Transmission Check. NO:The appropriate solenoids do not activate when selecting a specific gear. Diagnose the transmission control system. See Transmission Control System . (Group 9020-05.) ( 3 ) Transmission Check
Action: Check the operation of the transmission clutches. See Transmission Pressure Test . (Group 9020-25.) Are the requested transmission clutches activating when they are called for?
Result: YES:The requested transmission clutches activate when they are called for, but the machine will not shift to forward or reverse. Repair the transmission. See Transmission Disassemble . (Group 0350.) NO:The requested transmission clutches do not activate when they are called for but the respective solenoids are activating. Repair the transmission. See Transmission Control Valve Disassemble and Assemble . (Group 0350.)
<- Go to Section TOC
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Group 15: Diagnostic Information
Machine Creeps in Neutral 81
Machine Creeps in Neutral Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Transmission Control System Check. ( 2 ) Transmission Control System Check
Action: Check the transmission control system. See Transmission Solenoids and Sensors Tests . (Group 9015-20.) Select neutral. Do transmission solenoids activate?
Result: YES:Solenoids activate. Diagnose the transmission control system. See Transmission Control System . (Group 9020-05.) NO:Solenoids do not activate when selecting neutral. Go to Transmission Check. ( 3 ) Transmission Check
Action: Check the operation of the transmission clutches. See Transmission Clutch Drag Test . (Group 9020-25.) Are the transmission clutches dragging when Neutral is called for?
Result: YES:Repair the transmission and/or the transmission control valve assembly. See Transmission Disassemble , and see Transmission Control Valve Disassemble and Assemble . (Group 0350.) NO:Checks complete.
<- Go to Section TOC
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Engine Speed Too High During Torque Converter Stall 81
Engine Speed Too High During Torque Converter Stall Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Transmission Oil Level and Type Check. ( 2 ) Transmission Oil Level and Type Check
Action: Check transmission oil level and type. See Check Transmission Oil Level . (Operator’s Manual.) Are transmission oil type and level correct?
Result: YES:Go to Transmission Control System Check. NO:Adjust transmission oil to correct type and level. ( 3 ) Transmission Control System Check
Action: Check the transmission control system, and verify that the machine is going into gear. See Transmission Solenoids and Sensors Tests . (Group 9015-20.) When selecting a specific gear, do the appropriate transmission solenoids activate?
Result: YES:The appropriate solenoids activate. Go to Transmission Check. NO:The appropriate solenoids do not activate when selecting a specific gear. Diagnose the transmission control system. See Transmission Control System . (Group 9020-05.) ( 4 ) Transmission Check
Action: Check the operation of the transmission clutches. See Transmission Pressure Test . (Group 9020-25.) Are the requested transmission clutches activating when they are called for?
Result: YES:The requested transmission clutches activate when they are called for. Go to Torque Converter Valves Check. NO:The requested transmission clutches do not activate when they are called for. Repair the transmission. See Transmission Disassemble . (Group 0350.) ( 5 ) Torque Converter Valves Check
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Action: Check torque converter safety valve and torque converter back pressure valve. See Transmission Retarder Disassemble and Assemble . (Group 0360.) Are the torque converter safety valve and the torque converter back pressure valve damaged?
Result: YES:Repair or replace valves as required. See Transmission Retarder Disassemble and Assemble . (Group 0360.) NO:Go to Torque Converter Stall Speed Check. ( 6 ) Torque Converter Stall Speed Check
Action: Check torque converter stall speed. Perform Torque Converter Stall Test . (Group 9020-25.) Are stall speeds within specification?
Result: YES:Checks complete. NO:Replace torque converter. See Torque Converter Remove and Install . (Group 0360.)
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Engine Speed Too Low During Torque Converter Stall 81
Engine Speed Too Low During Torque Converter Stall Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Transmission Oil Level and Type Check. ( 2 ) Transmission Oil Level and Type Check
Action: Check transmission oil level and type. See Check Transmission Oil Level . (Operator’s Manual.) Are transmission oil type and level correct?
Result: YES:Go to Transmission Control System Check. NO:Adjust transmission oil to correct type and level. ( 3 ) Transmission Control System Check
Action: Check the transmission control system, and verify that the machine is going into gear. See Transmission Solenoids and Sensors Tests . (Group 9015-20.) When selecting a specific gear, do the appropriate transmission solenoids activate?
Result: YES:The appropriate solenoids activate. Go to Torque Converter Valves Check. NO:The appropriate solenoids do not activate when selecting a specific gear. Diagnose the transmission control system. See Transmission Control System . (Group 9020-05.) ( 4 ) Torque Converter Valves Check
Action: Check torque converter safety valve and torque converter back pressure valve. See Transmission Retarder Disassemble and Assemble . (Group 0360.) Are the torque converter safety valve and the torque converter back pressure valve damaged?
Result: YES:Repair or replace valves as required. See Transmission Retarder Disassemble and Assemble . (Group 0360.) NO:Go to Engine Power Check. ( 5 ) Engine Power Check
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Group 15: Diagnostic Information
Action: Check for low engine power by testing the torque converter. Perform the following tests: See Transmission Pump Flow Test . (Group 9020-25.) See Torque Converter—Inlet Pressure Test . (Group 9020-25.) See Torque Converter—Outlet Flow Test and Relief Pressure Test . (Group 9020-25.) Is low engine power suspected?
Result: YES:Test engine power. See Engine Does Not Develop Full Power . (Group 9010-15.) NO:Checks complete.
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Group 15: Diagnostic Information
Excessive Clutch Slippage and Chatter 81
Excessive Clutch Slippage and Chatter Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Transmission Control System Check. ( 2 ) Transmission Control System Check
Action: Check the transmission control system. See Transmission Solenoids and Sensors Tests . (Group 9015-20.) When selecting a specific gear, do the appropriate transmission solenoids activate?
Result: YES:The appropriate solenoids activate. Go to Transmission Check. NO:The appropriate solenoids do not activate when selecting a specific gear. Diagnose the transmission control system. See Transmission Control System . (Group 9020-05.) ( 3 ) Transmission Check
Action: Check the operation of the transmission clutches. See Transmission Pressure Test . (Group 9020-25.) Are the requested transmission clutches activating when they are called for?
Result: YES:The requested transmission clutches activate when they are called for. Repair the transmission. See Transmission Disassemble . (Group 0350.) NO:The requested transmission clutches do not activate when they are called for. Repair the transmission. See Transmission Disassemble . (Group 0350.) Oil Comes Out of Transmission Oil Fill Tube 81
Oil Comes Out of Transmission Oil Fill Tube Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Result: YES:Repair malfunction causing DTC(s). NO:Go to Transmission Oil Level Check. ( 2 ) Transmission Oil Level Check
Action: Check transmission oil level. See Check Transmission Oil Level . (Operator’s Manual.) Is transmission oil at correct level?
Result: YES:Go to Transmission Breather Check. NO:Adjust transmission oil to correct level. ( 3 ) Transmission Breather Check
Action: Check transmission breather for obstruction. See Transmission External Components . (Group 9020-15.) Is transmission breather obstructed?
Result: YES:Replace or clean breather. NO:Checks complete.
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Buzzing Noise from Transmission 81
Buzzing Noise from Transmission Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Transmission Oil Level and Type Check. ( 2 ) Transmission Oil Level and Type Check
Action: Check transmission oil level and type. See Check Transmission Oil Level . (Operator′s Manual.) Are transmission oil level and type correct?
Result: YES:Go to Transmission Control System Check. NO:Adjust transmission oil to correct level. ( 3 ) Transmission Control System Check
Action: Check the transmission control system. See Transmission Solenoids and Sensors Tests . (Group 9015-20.) When selecting a specific gear, do the appropriate transmission solenoids activate?
Result: YES:The appropriate solenoids activate. Go to Transmission Check. NO:The appropriate solenoids do not activate when selecting a specific gear. Diagnose the transmission control system. See Transmission Control System . (Group 9020-05.) ( 4 ) Transmission Check
Action: Check the operation of the transmission clutches. See Transmission Pressure Test . (Group 9020-25.) Are the requested transmission clutches activating when they are called for?
Result: YES:The requested transmission clutches activate when they are called for. Repair the transmission. See Transmission Disassemble . (Group 0350.) NO:The requested transmission clutches do not activate when they are called for. Repair the transmission. See Transmission Disassemble . (Group 0350.)
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Transmission Overheating in All Gears 81
Transmission Overheating in All Gears Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Transmission Oil Check. ( 2 ) Transmission Oil Check
Action: Check transmission oil type and level. See Check Transmission Oil Level . (Operator’s Manual.) Are transmission oil type and level correct?
Result: YES:Go to Transmission Oil Cooler Thermal Bypass Valve Operation Check NO:Adjust transmission oil to correct level. See Check Transmission Oil Level . (Operator’s Manual.) ( 3 ) Transmission Oil Cooler Thermal Bypass Valve Operation Check
Action: Check transmission oil cooler thermal bypass valve. See Transmission Oil Cooler Thermal Bypass Valve Temperature Test . (Group 9020-25.) Is transmission oil cooler thermal bypass valve working correctly?
Result: YES:Go to Oil Cooler Thermal Bypass Valve Pressure Check. NO:Repair or replace transmission oil cooler thermal bypass valve. ( 4 ) Transmission Oil Cooler Thermal Bypass Valve Pressure Check
Action: Check transmission oil cooler thermal bypass valve. See Transmission Oil Cooler Thermal Bypass Valve Pressure Test . (Group 9020-25.) Is transmission oil cooler thermal bypass valve working correctly?
Result: YES:Go to Transmission Oil Cooler Check. NO:Repair or replace transmission oil cooler thermal bypass valve. ( 5 ) Transmission Oil Cooler Check
Action: Check oil cooler for debris and bent fins. <- Go to Section TOC
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Group 15: Diagnostic Information
Are oil cooler fins clean and straight?
Result: YES:Go to Transmission Oil Cooler Restriction Check. NO:Clean and straighten oil cooler fins. ( 6 ) Transmission Oil Cooler Restriction Check
Action: Check transmission oil cooler for restrictions. See Transmission Oil Cooler Restriction Test . (Group 9020-25.) Is transmission oil cooler check within specifications?
Result: YES:Go to Cooling Fan Check. NO:Clean, repair, or replace transmission oil cooler. Perform Transmission Oil Cooler Remove and Install . (Group 0360.) ( 7 ) Cooling Fan Check
Action: Check for proper cooling fan operation. See Fan Drive System Operation . (Group 9025-05.) Is the cooling fan operating properly?
Result: YES:Go to Torque Converter Stator Check. NO:Diagnose and repair cooling system as required. See Hydraulic Fan Motor Not Working . (Group 9025-15.) ( 8 ) Torque Converter Stator Check
Action: Check torque converter stator for possible problems. See Torque Converter Stator Tests . (Group 9020-25.) Is the torque converter operating properly?
Result: YES:Checks complete. NO:Replace torque converter. See Torque Converter Remove and Install . (Group 0360.)
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Group 15: Diagnostic Information
Transmission Not Shifting Properly (Rough Shifts, Shifting at Too-Low or Too-High Speed) 81
Transmission Not Shifting Properly (Rough Shifts, Shifting at Too-Low or Too-High Speed) Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTCs. NO:Go to Transmission Oil Level Check. ( 2 ) Transmission Oil Level Check
Action: Check transmission oil level. See Check Transmission Oil Level . (Operator’s Manual.) Is transmission oil at correct level?
Result: YES:Go Transmission Calibration Check. NO:Adjust transmission oil to correct level. ( 3 ) Transmission Calibration Check
Action: Calibrate transmission control unit (TCU). See Electronic Clutch Calibration . (Group 9020-25.) Does transmission calibrate successfully?
Result: YES:Go to Accelerator Pedal Check. NO:Diagnose generated diagnostic code. ( 4 ) Accelerator Pedal Check
Action: Check accelerator pedal position sensor reading. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) Does sensor reading match accelerator pedal position?
Result: YES:Go to Transmission Control System Check. NO:Replace accelerator pedal. ( 5 ) Transmission Control System Check
Action: Check the transmission control system. See Transmission Solenoids and Sensors Tests . (Group 9015-20.) <- Go to Section TOC
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Group 15: Diagnostic Information
When selecting a specific gear, do the appropriate transmission solenoids activate?
Result: YES:The appropriate solenoids activate. Go to Transmission Check. NO:The appropriate solenoids do not activate when selecting a specific gear. Diagnose the transmission control system. See Transmission Control System . (Group 9020-05.) ( 6 ) Transmission Check
Action: Check the operation of the transmission clutches. Are the requested transmission clutches activating when they are called for? See Transmission Pressure Test . (Group 9020-25.)
Result: YES:The requested transmission clutches activate when they are called for. Go to Torque Converter Stall Check. NO:The requested transmission clutches do not activate when they are called for. Repair the transmission. See Transmission Disassemble . (Group 0350.) ( 7 ) Torque Converter Stall Check
Action: Check torque converter stall performance. See Torque Converter Stall Test . (Group 9020-25.) Is torque converter stall test result within specification?
Result: YES:Go to Torque Converter Stator Check. NO:Replace torque converter. Perform Transmission Disassemble . (Group 0350.) ( 8 ) Torque Converter Stator Check
Action: Check torque converter stator performance. See Torque Converter Stator Tests . (Group 9020-25.) Are torque converter stall test results within specifications?
Result: YES:Checks complete. NO:See Engine Speed Too High During Torque Converter Stall , or see Engine Speed Too Low During Torque Converter Stall . (Group 9020-15.)
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Transmission Will Not Make a Specific Shift 81
Transmission Will Not Make a Specific Shift Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Transmission Oil Level Check. ( 2 ) Transmission Oil Level Check
Action: Check transmission oil level. See Check Transmission Oil Level . (Operator’s Manual.) Is transmission oil at correct level?
Result: YES:Go to Transmission Control System Check. NO:Adjust transmission oil to correct level. ( 3 ) Transmission Control System Check
Action: Check the transmission control system. See Transmission Solenoids and Sensors Tests . (Group 9015-20.) When selecting a specific gear, do the appropriate transmission solenoids activate?
Result: YES:The appropriate solenoids activate. Go to Transmission Check. NO:The appropriate solenoids do not activate when selecting a specific gear. Diagnose the transmission control system. See Transmission Control System . (Group 9020-05.) ( 4 ) Transmission Check
Action: Check the operation of the transmission clutches. See Transmission Pressure Test . (Group 9020-25.) Are the requested transmission clutches activating when they are called for?
Result: YES:The requested transmission clutches activate when they are called for. Checks complete. NO:The requested transmission clutches do not activate when they are called for. Repair the transmission. See Transmission Disassemble . (Group 0350.)
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Section 9020 - POWER TRAIN
Group 15: Diagnostic Information
Transmission Retarder Does Not Function 81
Transmission Retarder Does Not Function Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Accelerator Pedal Check. ( 2 ) Accelerator Pedal Check
Action: Check accelerator pedal position sensor reading. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) Does sensor reading match accelerator pedal position?
Result: YES:Go to Transmission Control System Check. NO:Replace accelerator pedal. ( 3 ) Transmission Control System Check
Action: Check the transmission control system. When selecting a specific gear, do the appropriate transmission solenoids activate? See Transmission Solenoids and Sensors Tests . (Group 9015-20.)
Result: YES:The appropriate solenoids activate. Go to Transmission Speed Sensor Check. NO:The appropriate solenoids do not activate when selecting a specific gear. Diagnose the transmission control system. See Transmission Control System . (Group 9020-05.) ( 4 ) Transmission Speed Sensor Check
Action: Check transmission speed sensor. See Transmission Solenoids and Sensors Tests . (Group 9015-20.) Is transmission speed sensor output with specification?
Result: YES:Go to Retarder Control Valves Check. NO:Replace speed sensor. See Transmission Speed Sensors Remove and Install . (Group 0350.) ( 5 ) Retarder Control Valves Check
Action: Check retarder control valve for wear or damage. See Transmission Retarder Disassemble and Assemble . (Group 0305.) <- Go to Section TOC
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Group 15: Diagnostic Information
Is retarder control valve worn or damaged?
Result: YES:Repair or replace retarder control valve. See Transmission Retarder Disassemble and Assemble . (Group 0305.) NO:Checks complete.
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Group 15: Diagnostic Information
Transmission Retarder Weak 81
Transmission Retarder Weak Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Accelerator Pedal Check. ( 2 ) Accelerator Pedal Check
Action: Check accelerator pedal position sensor reading. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) Does sensor reading match accelerator pedal position?
Result: YES:Go to Transmission Control System Check. NO:Replace accelerator pedal. ( 3 ) Transmission Control System Check
Action: Check the transmission control system. When selecting a specific gear, do the appropriate transmission solenoids activate? See Transmission Solenoids and Sensors Tests . (Group 9015-20.)
Result: YES:The appropriate solenoids activate. Go to Transmission Speed Sensor Check. NO:The appropriate solenoids do not activate when selecting a specific gear. Diagnose the transmission control system. See Transmission Control System . (Group 9020-05.) ( 4 ) Transmission Speed Sensor Check
Action: Check transmission speed sensor. See Transmission Solenoids and Sensors Tests . (Group 9015-20.) Is transmission speed sensor output with specification?
Result: YES:Go to Retarder Control Valves Check. NO:Replace speed sensor. See Transmission Speed Sensors Remove and Install . (Group 0350.) ( 5 ) Retarder Control Valves Check
Action: Check retarder control valve for wear or damage. See Transmission Retarder Disassemble and Assemble . (Group 0305.) <- Go to Section TOC
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Group 15: Diagnostic Information
Is retarder control valve worn or damaged?
Result: YES:Repair or replace retarder control valve. See Transmission Retarder Disassemble and Assemble . (Group 0305.) NO:Go to Retarder Component Check. ( 6 ) Retarder Component Check
Action: Check internal components of retarder for wear or damage. See Transmission Disassemble . (Group 0350.) Are worn or damaged parts within the retarder?
Result: YES:Repair or replace necessary parts. See Transmission Retarder Disassemble and Assemble . (Group 0350.) NO:Checks complete.
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Group 15: Diagnostic Information
Retarder Stays On When Not Requested 81
Retarder Stays On When Not Requested Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Accelerator Pedal Check. ( 2 ) Accelerator Pedal Check
Action: Check accelerator pedal position sensor reading. See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) Does sensor reading match accelerator pedal position?
Result: YES:Go to Transmission Control System Check. NO:Replace accelerator pedal. ( 3 ) Transmission Control System Check
Action: Check the transmission control system. See Transmission Solenoids and Sensors Tests . (Group 9015-20.) When selecting a specific gear, do the appropriate transmission solenoids activate?
Result: YES:The appropriate solenoids activate. Go to Transmission Speed Sensor Check. NO:The appropriate solenoids do not activate when selecting a specific gear. Diagnose the transmission control system. See Transmission Control System . (Group 9020-05.) ( 4 ) Transmission Speed Sensor Check
Action: Check transmission speed sensor. See Transmission Solenoids and Sensors Tests . (Group 9015-20.) Is transmission speed sensor output with specification?
Result: YES:Go to Retarder Control Valves Check. NO:Replace speed sensor. See Transmission Speed Sensors Remove and Install . (Group 0350.) ( 5 ) Retarder Control Valves Check
Action: Check retarder control valve for wear or damage. See Transmission Retarder Disassemble and Assemble . (Group 0305.) <- Go to Section TOC
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Group 15: Diagnostic Information
Is retarder control valve worn or damaged?
Result: YES:Repair or replace retarder control valve. Perform Transmission Retarder Disassemble and Assemble . (Group 0305.) NO:Checks complete.
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Group 25: Tests
Transmission Retarder Too Aggressive 81
Transmission Retarder Too Aggressive Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Operation: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Repair malfunction causing DTC(s). NO:Go to Transmission Control System Check. ( 2 ) Transmission Control System Check
Action: Check the transmission control system. See Transmission Solenoids and Sensors Tests . (Group 9015-20.) When selecting a specific gear, do the appropriate transmission solenoids activate?
Result: YES:The appropriate solenoids activate. Go to Retarder Control Valve Check. NO:The appropriate solenoids do not activate when selecting a specific gear. Diagnose the transmission control system. See Transmission Control System . (Group 9020-05.) ( 3 ) Retarder Control Valve Check
Action: Check retarder control valve for sticking, wear, or damage. See Transmission Retarder Remove and Install . (Group 0305.) Is retarder control valve sticking, worn, or damaged?
Result: YES:Repair or replace retarder control valve. Perform Transmission Retarder Remove and Install . (Group 0305.) NO:Checks complete.
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Group 25: Tests
Group 25 - Tests Transmission Warmup Procedure Specifications SPECIFICATIONS Transmission Oil Operating Temperature
82—95°C 180—200°F
Torque Convertor Oil Output Temperature
95—125°C 200—260°F
CAUTION: Avoid personal injury from unexpected machine movement. Perform procedure in an open area away from other people and machines. IMPORTANT: Never stall torque converter for more than 10 seconds. Do not allow transmission temperature (SUMP TEMP) to exceed 100°C (212°F). Transmission damage will result if temperature is allowed to exceed the specification. NEVER stall torque converter in reverse. Drive shaft, transfer case, or differential damage may result. Reverse gear ratio is lower than 1st gear ratio, and excessive torque will be transferred to the drive shaft, transfer case, or differential. [1] - Start engine. [2] - Apply the park brake. See Sealed Switch Module (SSM) . (Operator’s Manual.) [3] - Monitor torque converter output oil temperature (TC OUT) and engine rpm using the CMU, see CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [4] - Apply the service brake throughout the transmission warmup procedure. [5] - Release park brake. [6] - Select F (forward) on the sealed switch module (SSM). [7] - Apply the park brake. [8] →NOTE: If the right cooling fan is allowed to operate during the warmup procedure, transmission oil operating temperature will be difficult to reach. The chassis control unit (CCU) cuts flow to the cooling fan during dump body operation. Operation of the dump body is essential to reaching the specified transmission oil operating temperature. Operate dump body raise and lower functions during warmup. [9] IMPORTANT: Do not drive through the parking brake for more than 1-2 lengths of the truck during the procedure Apply Accelerator Pedal only 10-20% to stall converter against the service and parking brake. [10] -
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Group 25: Tests
IMPORTANT: Monitor torque converter oil output temperature, do not exceed torque converter oil output temperature of 110°C (230°F). Torque converter damage will result if temperature is allowed to exceed the specification. Select Neutral on the SSM once the converter temperature reaches 105°C (220°F) [11] →NOTE: Engine high idle increase the oil flow through the converter and the cooling rate of the converter oil. Continue to hold Accelerator Pedal at 10-20% allowing engine to speed to high idle until the converter oil temperature is within 10° of the SUMP oil temperature. [12] - Repeat steps 6—11 until transmission oil operating temperature (SUMP TEMP) reaches specification. Item
Measurement
Specification
Transmission Oil Operating
Temperature
82—95°C 180—200°F
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Group 25: Tests
JT02156A Digital Pressure/Temperature Analyzer Kit Installation LEGEND: 1 JT02158 Digital Pressure/Temperature Analyzer 2 JT02161 Transducer 3500 kPa (35 bar) (500 psi) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
JT02158 Digital Pressure/Temperature Analyzer and Transducers Service Equipment and Tools JT02156A Digital Pressure/Temperature Analyzer Kit JT02158 Digital Pressure/Temperature Analyzer JT02159 6.1 m (20 ft.) Cable with Couplers JT02161 Transducer 3500 kPa (35 bar) (500 psi) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02166 Compression Test Adapter 235400 Thermo-Coupler 312883 Carry Case
JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi) (ordered separately) →NOTE: It is recommended that D05200ST Hydraulic Gauge Protector and Snubber be used with JT02161 to possibly protect and extend the life of the product. Hydraulic Gauge Protector and Snubber D05200ST Protect gauges in diagnostic test kits, 0-600 plus/minus 30 psi. Use the JT02158 Digital Pressure/Temperature Analyzer (1) in place of analog gauges and a separate temperature reader. Digital Pressure/Temperature Analyzer JT02158 Used to check hydraulic pressure and temperature. Transducers (2) are temperature sensitive. Allow transducer to warm to system temperature. After it is warmed and no pressure applied, push sensor zero button for 1 second to set the true zero point. Transducer 3500 kPa (35 bar) (500 psi) JT02161 Used to check hydraulic pressure and temperature. Transducer 35 000 kPa (350 bar) (5000 psi) JT02162 Used to check hydraulic pressure and temperature. When different pressures are used, turn selector to the OFF position for 2 seconds and then to the selected pressure range. Readings will be inaccurate if the proper range for transducer is not used.
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Group 25: Tests
Transmission Pressure Test Specifications SPECIFICATIONS Transmission Oil Normal Operating Temperature
80—90°C 175—195°F
Engine Speed—Slow Idle
900 rpm
Lube Pressure
1.5 bar 150 kPa 1.5 psi
Torque Converter Lockup Pressure
13.5—14.5 bar 1350—1450 kPa 196—210 psi
Clutch V Pressure
15—17 bar 1500—1700 kPa 218—247 psi
Hydraulic System Pressure Pressure
15—17 bar 1500—1700 kPa 218—247 psi
Clutch E Pressure
15—17 bar 1500—1700 kPa 218—247 psi
Clutch G Pressure
15—17 bar 1500—1700 kPa 218—247 psi
Clutch C Pressure
15—17 bar 1500—1700 kPa 218—247 psi
Clutch F Pressure
15—17 bar 1500—1700 kPa 218—247 psi
Clutch A Pressure
15—17 bar 1500—1700 kPa 218—247 psi
Clutch R Pressure
15—17 bar 1500—1700 kPa 218—247 psi
Clutch B Pressure
15—17 bar 1500—1700 kPa 218—247 psi
Clutch D Pressure
15—17 bar 1500—1700 kPa 218—247 psi
Essential Tools ESSENTIAL TOOLS 202839 1/2 Quick Coupler x 7/16-20 ORB
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure/Temperature Analyzer JT02161 Transducer 3500 kPa (35 bar) (500 psi) JT02159 6.1 m (20 ft.) Cable with Couplers
<- Go to Section TOC
Section 9020 page 81
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Transmission Test Port Location LEGEND: 1 2 3 4 5 6 7 8 9 10 11 12
Lube Pressure Test Port Torque Converter Lockup Test Port Clutch V Test Port System Pressure Test Port Clutch E Test Port Clutch G Test Port Clutch C Test Port Clutch F Test Port Clutch A Test Port Clutch R Test Port Clutch B Test Port Clutch D Test Port
For more information on the location of the transmission test port locations, see Transmission External Components . (Group 9020-15.) Active Solenoids ACTIVE SOLENOIDS Driving Direction
Speed
Y60
Forward
1
X
2
Y61
Y62
X
3
X
4 5
X
3 4 <- Go to Section TOC
X X X
Y64
Engaged Clutches
X
V, A, F
X
X
V, B, F
X
X
V, C, F
X
X
V, D, F
X X
Y67
X
X
8
2
Y66
X
7
1
Y65
X
6
Reverse
Y63
X
X
V, A, E
X
X
V, B, E
X
X
V, C, E
X
X
V, D, E
X
X
R, A, F
X
X
R, B, F
X
X
R, C, F
X
X
R, D, F
Section 9020 page 82
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
X — Indicates solenoid is electrically ON. Transmission Engagement Chart Test Pressures Test Port
Pressure Oil
Required Pressure
1
Lube Pressure
1.5 bar 150 kPa 1.5 psi
2
Torque Converter Lockup
13.5—14.5 bar 1350—1450 kPa 196—210 psi
3
Clutch V
15—17 bar 1500—1700 kPa 218—247 psi
4
Hydraulic System Pressure
15—17 bar 1500—1700 kPa 218—247 psi
5
Clutch E
15—17 bar 1500—1700 kPa 218—247 psi
6
Clutch G
15—17 bar 1500—1700 kPa 218—247 psi
7
Clutch C
15—17 bar 1500—1700 kPa 218—247 psi
8
Clutch F
15—17 bar 1500—1700 kPa 218—247 psi
9
Clutch A
15—17 bar 1500—1700 kPa 218—247 psi
10
Clutch R
15—17 bar 1500—1700 kPa 218—247 psi
11
Clutch B
15—17 bar 1500—1700 kPa 218—247 psi
12
Clutch D
15—17 bar 1500—1700 kPa 218—247 psi
[1] - With engine OFF. Install 202839 Quick Coupler in each clutch pressure port to be tested (1—12). 1/2 Quick Coupler x 7/16-20 ORB 202839 Installed in pressure port for testing equipment attachment. [2] - Attach JT02161 Transducer, JT02159 Cable with Couplers, and JT02158 Digital Pressure/Temperature Analyzer to quick coupler of pressure port to be tested. Transducer 3500 kPa (35 bar) (500 psi) JT02161 Connect to pressure port. 6.1 m (20 ft.) Cable with Couplers JT02159 Cable extension between transducer and digital pressure and temperature analyzer. Digital Pressure/Temperature Analyzer JT02158 To measure pressure. [3] - Start machine and warm up transmission to normal operating temperature. See Transmission Warmup Procedure . (Group 9020-25.) <- Go to Section TOC
Section 9020 page 83
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Item
Measurement
Specification
Transmission Oil Normal Operating
Temperature
80—90°C 175—195°F
[4] CAUTION: Avoid personal injury from unexpected machine movement. Perform procedure in an open area away from other people and machines. Operate machine at specification and record test results. Travel direction and gear selection is performed using the sealed switch module (SSM). See Shifting the Transmission . (Operator′s Manual.) Item
Measurement
Specification
Engine—Slow Idle
Speed
900 rpm
If transmission pressures are not to specification, check transmission charge pump and/or main pressure regulator. See Transmission Control Valve Disassemble and Assemble and Oil Pump Disassemble and Assemble . (Group 0350.)
<- Go to Section TOC
Section 9020 page 84
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Transmission Clutch Drag Test Specifications SPECIFICATIONS Transmission Oil Normal Operating Temperature
80—90°C
Transmission Oil Normal Operating
175—195°F
Engine Fast Idle Speed
2250 rpm
Transmission Clutch Residual Pressure Pressure
1 bar (15 psi)
Essential Tools ESSENTIAL TOOLS 202839 1/2 Quick Coupler x 7/16-20 ORB
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02161 Transducer 3500 kPa (35 bar) (500 psi) JT02159 6.1 m (20 ft.) Cable with Couplers JT02158 Digital Pressure/Temperature Analyzer
The clutch drag test allows the technician to diagnose a machine that “creeps” in neutral. Clutch plates may be warped and dragging, or a clutch may have pressure in it when it should not be present. For more information on the transmission test port locations, see Transmission External Components . (Group 9020-15.) [1] -
Transmission Test Port Location LEGEND: 1 2 3 4 5 6 <- Go to Section TOC
Clutch V Test Port Clutch E Test Port Clutch C Test Port Clutch F Test Port Clutch A Test Port Clutch R Test Port Section 9020 page 85
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
7 Clutch B Test Port 8 Clutch D Test Port With machine OFF, install 202839 Quick Couplers in required ports according to table. 1/2 Quick Coupler x 7/16-20 ORB 202839 Installed in pressure port for testing equipment attachment. [2] - Attach JT02161 Transducer, JT02159 Cable with Couplers, and JT02158 Digital Pressure/Temperature Analyzer to quick coupler of pressure port to be tested. Transducer 3500 kPa (35 bar) (500 psi) JT02161 Connect to pressure port. 6.1 m (20 ft.) Cable with Couplers JT02159 Cable extension between transducer and digital pressure and temperature analyzer. Digital Pressure/Temperature Analyzer JT02158 To measure pressure. [3] - Start machine and warm up transmission to normal operating temperature. See Transmission Warmup Procedure . (Group 9020-25.) Item
Measurement
Specification
Transmission Oil Normal Operating
Temperature
80—90°C 175—195°F
[4] CAUTION: Avoid personal injury from unexpected machine movement. Perform procedure in an open area away from other people and machines. Operate the machine in an open area away from people or other machines. [5] - Stop machine on a level, hard surface and shift to neutral. Release service brake and park brake. [6] - Operate engine at fast idle for 1 minute. Watch the tires to see if the machine “creeps” forward or backward. Item
Measurement
Specification
Engine Fast Idle
Speed
2250 rpm
[7] - Operate machine in a area large enough to permit driving into 4th gear. [8] - Observe the digital pressure and temperature analyzer as pressure is exhausted from the clutches. Pressure must drop to specification when the clutches go off. Item
Measurement
Specification
Transmission Clutch Residual Pressure
Pressure
1 bar 15 psi
If machine “creeps,” or there is residual pressure when clutch is OFF, check transmission clutch pressures. See Transmission Pressure Test . (Group 9020-25.)
<- Go to Section TOC
Section 9020 page 86
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Transmission Pump Flow Test Specifications SPECIFICATIONS Transmission Oil Temperature
80—90°C 175—195°F
Engine Speed—Fast Idle
2250 rpm
Engine Speed—Slow Idle
900 rpm
Transmission Position
Neutral
Transmission Pump Flow—Slow Idle
42 L/min 11 gpm
Transmission Pump Flow—Fast Idle
112 L/min 30 gpm
Essential Tools ESSENTIAL TOOLS JDG596 Filter Adapter JT07148 Digital Hydraulic Flowmeter JDG596A-1 Spacer and Sealing Washer Kit
The purpose of this test is to determine transmission pump flow rate and performance. [1] - Park and Prepare For Service Safely . (Group 9000-01.) [2] - Remove shield covering transmission filter housing. [3] -
Transmission LEGEND: 1 Return Line 2 Transmission Oil Filter Housing 3 Supply Line Remove return line (1) and supply line (3) from transmission oil filter housing (2). Plug open ports on transmission oil filter housing. [4] - Install JT07148 Digital Hydraulic Flowmeter inline with return line (1) and supply line (3). <- Go to Section TOC
Section 9020 page 87
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Digital Hydraulic Flowmeter Tester JT07148 Used to measure oil flow. [5] - Check transmission oil level. See Check Transmission Oil Level . (Operator’s Manual.) [6] IMPORTANT: Before starting engine, make sure flowmeter loading valve is open. Pump can be damaged if engine is started with loading valve closed. Perform transmission oil warmup procedure. See Transmission Warmup Procedure . (Group 9020-25.) Item
Measurement
Specification
Transmission Oil
Temperature
74—86°C 166—186°F
[7] - Operate engine at slow idle with transmission in neutral. Item
Measurement
Specification
Engine—Slow Idle
Speed
900 rpm
Transmission
Position
Neutral
[8] - Measure pump flow. Item
Measurement
Specification
Transmission Pump—Slow Idle
Flow (minimum)
42 L/min 11 gpm
[9] - Operate engine at fast idle with transmission in neutral. Item
Measurement
Specification
Engine—Fast Idle
Speed
2250 rpm
Transmission
Position
Neutral
[10] - Measure pump flow. Item
Measurement
Specification
Transmission Pump—Fast Idle
Flow (minimum)
112 L/min 30 gpm
[11] - Remove test equipment and install transmission oil filter. Low transmission pump flow can be caused by: Low oil level in transmission. Cold transmission oil. Plugged suction screen. Air leak in pump suction tube. Worn transmission pump.
<- Go to Section TOC
Section 9020 page 88
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Transmission Oil Cooler Restriction Test Specifications SPECIFICATIONS Transmission Oil Operating Temperature
80—90°C 175—195°F
Engine Speed—Slow Idle
900 rpm
Engine Speed—Fast Idle
2250 rpm
Transmission Oil Cooler Flow—Slow Idle
22 L/min 6 gpm
Transmission Oil Cooler Flow—Fast Idle
93 L/min 25 gpm
Essential Tools ESSENTIAL TOOLS JT05418 Industrial Flow Test Kit
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07148 Digital Hydraulic Flowmeter
The transmission oil cooler restriction test allows the technician to diagnose a restricted transmission oil cooler. [1] -
Transmission Oil Cooler LEGEND: 1 Transmission Oil Cooler 2 Oil Cooler Return Line Disconnect oil cooler return line (2) at the transmission oil cooler (1) and install JT07148 Digital Hydraulic Flowmeter using fittings from JT05418 Industrial Flow Test Kit. Industrial Flow Test Kit <- Go to Section TOC
Section 9020 page 89
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
JT05418 Fittings to connect flow meter. Digital Hydraulic Tester JT07148 Check transmission cooler oil flow pressure. [2] - Start machine and warm transmission to specification. Perform Transmission Warmup Procedure . (Group 9020-25.) Item
Measurement
Specification
Transmission Oil Operating
Temperature
80—90°C 175—195°F
[3] - Operate engine at slow idle with transmission in neutral. Item
Measurement
Specification
Engine—Slow Idle
Speed
900 rpm
[4] - Measure pump flow and compare reading to specification. Item
Measurement
Specification
Oil Cooler—Slow Idle
Flow Rate
22 L/min 6 gpm
[5] - Operate engine at fast idle with transmission in neutral. Item
Measurement
Specification
Engine—Fast Idle
Speed
2250 rpm
[6] - Measure pump flow and compare reading to specification. Item
Measurement
Specification
Oil Cooler—Fast Idle
Flow Rate
93 L/min 25 gpm
If flow rate is less than specification, the transmission oil cooler is restricted. See Transmission Oil Cooler Remove and Install . (Group 0510.)
<- Go to Section TOC
Section 9020 page 90
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Transmission Oil Cooler Thermal Bypass Valve Temperature Test Specifications SPECIFICATIONS Engine Speed
2250 rpm
Thermal Bypass Valve Begins to Open Temperature
67—70°C 152—158°F
Thermal Bypass Valve Fully Open Temperature
76—79°C 168—174°F
Essential Tools ESSENTIAL TOOLS JT07253 Non-Contact Temperature Measuring Gun
This test measures operating temperature of the thermal bypass valve to ensure that it is working properly. [1] →NOTE: Transmission oil temperature must be below 70°C (158°F) before performing this test. Allow oil to cool before proceeding.
Transmission Oil Cooler Thermal Bypass Valve LEGEND: 1 Thermal Bypass Valve Inlet 2 Transmission Oil Cooler Inlet 3 Transmission Oil Cooler Outlet Measure and record temperature at thermal bypass valve inlet and transmission oil cooler inlet and outlet (1—3) using JT07253 <- Go to Section TOC
Section 9020 page 91
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Non-Contact Temperature Measuring Gun. Non-Contact Temperature Measuring Gun JT07253 Used to take temperature readings. [2] →NOTE: Temperatures measured at thermal bypass valve and transmission oil cooler may not correspond with reading on CMU. Use temperature reading from CMU only as a guide. [3] - Disable transmission auto mode and clutch cut-off. [4] - Apply service brakes. [5] - Release park brake and shift transmission into forward (F). [6] IMPORTANT: Avoid possible machine damage. As oil temperature rises, continue to monitor oil temperature at thermal bypass valve inlet and transmission oil cooler inlet and outlet. DO NOT allow transmission oil temperature to exceed 100°C (212°F) at the thermal bypass valve. While fully applying service brakes, operate engine at the specified test speed specification for 30 seconds. Item
Measurement
Specification
Engine
Speed
2250 rpm
[7] - Reduce engine speed and shift transmission into neutral. [8] - Allow engine to run for 15 seconds at reduced speed, then repeat process to slowly warm transmission oil. [9] - As the thermal bypass valve opens, warm oil will be routed to transmission oil cooler inlet (2). Measure temperature at the transmission oil cooler inlet. The temperature increase will be similar to that observed at the thermal bypass valve. Compare temperature to specification. Item
Measurement
Specification
Thermal Bypass Valve Begins to Open
Temperature
67—70°C 152—158°F
[10] - As oil temperature increases, the thermal bypass valve will continue to open until oil temperature reaches specification. Item
Measurement
Specification
Thermal Bypass Valve Fully Open
Temperature
76—79°C 168—174°F
[11] - Measure temperature at the transmission oil cooler outlet (3). As oil passes through the transmission oil cooler, a temperature differential should be observed between the transmission oil cooler inlet and outlet. Observations: If the thermal bypass valve is stuck in the open position, the temperature measured at the transmission oil cooler inlet will be below the thermal bypass valve opening temperature. In this condition, it will take a relatively long period of time to warm the transmission oil. If the thermal bypass valve is stuck in the closed position, the temperature measured at the thermal bypass valve will rise above the thermal bypass valve full-open temperature. In this condition, it will take a relatively short period of time to warm the transmission oil. If thermal bypass valve does not meet specifications, repair or replace as necessary, and repeat test.
<- Go to Section TOC
Section 9020 page 92
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Transmission Oil Cooler Thermal Bypass Valve Pressure Test Specifications SPECIFICATIONS Transmission Oil Temperature
80—90°C 175—195°F
Transmission FNR Position
Neutral
Engine Speed—Slow Idle
900 rpm
Transmission Oil Cooler Thermal Bypass Valve Pressure
958 kPa 10 bar 139 psi
Essential Tools ESSENTIAL TOOLS JT02158 Digital Pressure and Temperature Analyzer JT02161 Transducer 3500 kPa (35 bar) (500 psi) Quick Couplers 4-M10 x 1F80X-S (7/16 -20 M 37° x M10 ORB)
Test Connections LEGEND: 1 Transmission Oil Cooler 2 Transmission Oil Cooler Inlet 3 Thermal Bypass Valve The purpose of this test is to check the pressure of the thermal bypass valve and restriction beyond thermal bypass valve. [1] - Park And Prepare For Service Safely . (Group 9000-01.) [2] -
<- Go to Section TOC
Section 9020 page 93
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
CAUTION: 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. Disconnect transmission oil cooler inlet (2) at the transmission oil cooler (1). Plug transmission oil cooler. [3] - Install a quick coupler at transmission oil cooler inlet (2). [4] - Install JT02161 Transducer 3500 kPa (35 bar) (500 psi) and JT02158 Digital Pressure and Temperature Analyzer to quick couplers. See JT02156A Digital Pressure/Temperature Analyzer Kit Installation . (Group 9025-25.) Digital Pressure And Temperature Analyzer JT02156A Checking Pressure Transducer JT02161 3500 kPa (35 bar) (500 psi) Checking Pressure Quick Couplers 4-M10 X 1F80X-S (7/16 -20 M 37° x M10 ORB) To connect transducers [5] - Check transmission oil level. See Check Transmission Oil Level . (Operator’s Manual.) [6] →NOTE: Observe pressure reading during warmup. Pressure should start out low. When thermal bypass valve opens, pressure will increase. Warm transmission oil to specification. See Transmission Warmup Procedure . (Group 9020-25.) Item
Measurement
Specification
Transmission Oil
Temperature
80—90°C 175—195°F
[7] - When oil temperature reaches specification, shift transmission into neutral and operate engine at slow idle. Item
Measurement
Specification
Transmission FNR
Position
Neutral
Engine—Slow Idle
Speed
900 rpm
[8] - Record pressure and compare to specification. Item
Measurement
Specification
Transmission Oil Cooler Thermal Bypass Valve Pressure
Pressure
958 kPa 10 bar 139 psi
If pressure is low, remove, inspect and clean thermal bypass valve. Replace valve if necessary.
<- Go to Section TOC
Section 9020 page 94
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Torque Converter—Inlet Pressure Test Specifications SPECIFICATIONS Transmission FNR Position
Forward
Engine Speed
1000 rpm
Torque Converter—Inlet Pressure
450—600 kPa 4.5—6 bar 65—87 psi
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02161 Transducer 3500 kPa (35 bar) (500 psi) JT02158 Digital Pressure and Temperature Analyzer Installation Male Quick Coupler Plug M14 x 1.5
[1] - Park and Prepare for Service Safely . (Group 9000-01.) [2] CAUTION: 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.
Torque Converter Test Port <- Go to Section TOC
Section 9020 page 95
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
LEGEND: 1 Torque Converter Test Port Remove plug from torque converter test port (1) and install Male Quick Coupler Plug M14 x 1.5 and JT02161 Transducer 3500 kPa (35 bar) (500 psi). Male Quick Coupler Plug M14 X 1.5 Used for connecting the temperature analyzer. Transducer 3500 kPa (35 bar) (500 psi) JT02161 Used for connecting the temperature analyzer. [3] - Install JT02158 Digital Pressure and Temperature Analyzer to quick coupler in the torque converter test port. See JT02156A Digital Pressure/Temperature Analyzer Kit Installation . (Group 9025-25.) Digital Pressure and Temperature Analyzer Installation JT02156A Used for monitoring pressure. [4] - Perform transmission oil warmup procedure. See Transmission Warmup Procedure . (Group 9020-25.) [5] - Apply park brake, service brakes, and select F (forward) on the sealed switch module (SSM). Item
Measurement
Specification
Transmission FNR
Position
Forward
[6] - Increase engine to specification. Item
Measurement
Specification
Engine
Speed
1000 rpm
[7] - Record torque converter—inlet pressure. Item
Measurement
Specification
Torque Converter—Inlet
Pressure
450—600 kPa 4.5—6 bar 65—87 psi
Low torque converter—inlet pressure can be caused by: Torque converter minimum pressure regulator valve set too low, stuck open, or spring broken or weak. Transmission pump worn. Perform Transmission Pump Flow Test . (Group 9020-25.) Control valve or valve gasket leakage. Remove and inspect. See Transmission Control Valve Remove and Install . (Group 0360.) Torque converter relief valve set too low, stuck open, or spring broken or weak. See Torque Converter—Outlet Flow Test and Relief Pressure Test . (Group 9020-25.)
<- Go to Section TOC
Section 9020 page 96
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Torque Converter—Outlet Flow Test and Relief Pressure Test Specifications SPECIFICATIONS Engine Speed—Slow Idle
900 rpm
Engine Speed—Fast Idle
2250 rpm
Transmission Oil Temperature
74—86°C 166—186°F
Torque Converter—Outlet Flow
50 L/min 14.5 gpm
Torque Converter Relief Pressure
400—700 kPa 4—7 bar 58—102 psi
Torque Converter—Outlet Temperature
100°C 212°F
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS 38H1281 Union (-16 M ORFS x -16 M ORFS) (Parker No. 16HLO-S) JT07148 Digital Hydraulic Flowmeter
Prior to performing torque converter outlet flow test and relief pressure test, verify the following: Correct transmission oil level. See Check Transmission Oil Level . (Operator’s Manual.) Transmission pump flow. See Transmission Pump Flow Test . (Group 9020-25.) [1] - Park and Prepare for Service Safely . (Group 9000-01.) [2] CAUTION: 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.
<- Go to Section TOC
Section 9020 page 97
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Test Connections LEGEND: 1 90° Elbow Fitting 2 Torque Converter Outlet Hydraulic Line Disconnect torque converter outlet hydraulic line (2) from 90° elbow fitting (1) and install JT07148 Digital Hydraulic Flowmeter inline with the torque converter out cooling circuit. See Hydraulic System Component Location . (Group 9025-15.) Digital Hydraulic Flowmeter JT07148 To measure hydraulic fluid flow. [3] IMPORTANT: Prevent pump damage. Check that the loading valve on JT07148 Digital Hydraulic Flowmeter is open before starting engine. Pump can be damaged if engine is started with loading valve closed. Perform transmission oil warm-up procedure. See Transmission Warmup Procedure . (Group 9020-25.) Item
Measurement
Specification
Transmission Oil
Temperature
74—86°C 166—186°F
[4] - Release park brake and select F (forward) using the sealed switch module (SSM). [5] - Apply the park brake. [6] - Increase engine speed to specification and hold for 10 seconds. Item
Measurement
Specification
Engine (Fast Idle)
Speed
2250 rpm
<- Go to Section TOC
Section 9020 page 98
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
[7] IMPORTANT: Monitor torque converter outlet temperature, do not exceed torque converter output specification. Torque converter damage will result if oil temperature is allowed to exceed the specification. View torque converter outlet temperature on the CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU)—TCU Readings . (Group 9015-16.) Item
Measurement
Specification
Torque Converter Outlet
Temperature
100°C 212°F
[8] - Measure torque converter outlet flow. Document readings and compare to specifications. Item
Measurement
Specification
Torque Converter Outlet
Flow
50 L/min 13 gpm
[9] - Turn ignition OFF. [10] →NOTE: Perform relief pressure test only if machine did not meet specifications for torque converter inlet pressure test. →NOTE: An external gauge needs to be used in place of the supplied gauge on JT07148 Digital Hydraulic Flowmeter (4). The pressure specification of the internal gauge is out of range of the converter relief valve specification. Use of internal gauge will result in inaccurate pressure readings. LEGEND: 3 Hydraulic Pressure Line 4 JT07148 Digital Hydraulic Flowmeter
Pressure Line to JT07148 Digital Hydraulic Flowmeter Disconnect hydraulic pressure line (3) from JT07148 Digital Hydraulic Flowmeter (4) and install a 200 psi pressure gauge to hydraulic pressure line (3). [11] - Close loading valve on JT07148 Digital Hydraulic Flowmeter (4). [12] - Start engine and operate engine at specification with transmission in neutral. Item
Measurement
Specification
Engine (Slow Idle)
Speed
900 rpm
[13] IMPORTANT: Monitor torque converter outlet temperature. Do not exceed torque converter output specification. Torque converter damage will result if oil temperature is allowed to exceed the specification.
<- Go to Section TOC
Section 9020 page 99
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
View torque converter output temperature on the CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU)—TCU Readings . (Group 9015-16.) Item
Measurement
Specification
Torque Converter—Outlet
Temperature
100°C 212°F
[14] - Record torque converter relief pressure. Item
Measurement
Specification
Torque Converter Relief
Pressure
400—700 kPa 4—7 bar 58—102 psi
If torque converter outlet flow or converter relief valve pressure is low, check the following: Air leak in pump suction tube. Plugged thermal bypass valve or lube passage. Torque converter relief valve stuck open, or spring weak or broken. Transmission control valve gasket leakage. Remove and inspect gasket. See Transmission Control Valve Remove and Install . (Group 0360.) Plugged suction screen. Clean transmission pump suction screen. See Transmission Remove and Install . (Group 0300.) Torque converter leakage. See Torque Converter Remove and Install . (Group 0350.)
<- Go to Section TOC
Section 9020 page 100
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Torque Converter Stall Test Specifications SPECIFICATIONS Transmission Sump Oil Operating Temperature
82—95°C 180—200°F
Engine Speed—Slow Idle
900 rpm
Engine Speed—Fast Idle
2250 rpm
Torque Converter Stall Speed
1615—1665 rpm (370E) 1653—1753 rpm (410E) 1716—1816 rpm (460E)
Torque Converter Oil Output Temperature
95—125°C 200—260°F
[1] CAUTION: Avoid personal injury from unexpected machine movement. Perform procedure in an open area away from other people and machines. IMPORTANT: Transmission damage will result if temperature is allowed to exceed the specification. Never stall torque converter for more than 10 seconds. Do not allow transmission temperature to exceed 100°C (212°F). Avoid drive shaft or transfer case damage. NEVER perform stall test in reverse. Reverse gear ratio is lower than 1st gear ratio, and excessive torque will be transferred to the drive shaft, transfer case, or differential. Park and Prepare for Service Safely . (Group 9000-01.) [2] - Check and correct all oil levels. [3] IMPORTANT: For consistency turn off A/C and warm-up trans sump oil; do not falls below transmission sump oil temperature of 82°C (180°F); prior to the stall speed measurement Start engine and perform the Transmission Warmup Procedure . (Group 9020-25.) Item
Measurement
Specification
Transmission Sump Oil
Temperature
82—95°C 180—200°F
[4] - Verify that idle speeds are correct. Item
Measurement
Specification
Engine—Slow Idle
Speed
900 rpm
Engine—Fast Idle
Speed
2250 rpm
[5] - To check stall speed: a. In the MAIN MENU, select engine speed using the up or side arrow buttons b. Apply the park brake. See Sealed Switch Module (SSM) . (Operator’s Manual.) IMPORTANT: Monitor torque converter oil output temperature; do not exceed torque converter oil output temperature of 110°C (230°F). Torque converter damage will result if temperature is allowed to exceed the specification. Monitor torque converter output oil temperature (TC OUT) and engine rpm using the CMU, see CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) <- Go to Section TOC
Section 9020 page 101
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
d. Apply the service brake throughout the transmission warmup procedure. e. Release park brake. f. Select F (forward) on the sealed switch module (SSM). g. Apply the park brake. h. Increase engine speed to specification and hold for 10 seconds against the service and park brake. Item
Measurement
Specification
Engine—Fast Idle
Speed
2250 rpm
IMPORTANT: Monitor torque converter oil output temperature; do not exceed torque converter oil output temperature of 110°C (230°F). Torque converter damage will result if temperature is allowed to exceed the specification.
i. Record the torque converter stall speed at which the engine stabilizes and compare to specification. Item
Measurement
Specification
Torque Converter Stall
Speed (370E)
1615—1665 rpm
Speed (410E)
1653—1753 rpm
Speed (460E)
1716—1816 rpm
j. Release accelerator pedal and select N (neutral) on the SSM. Increase engine speed to 1500 rpm for 30 seconds for cooldown of the torque converter oil to a specification. k. Test complete. Park machine. [6] - Repeat the stall measurement test for one time. [7] - If the torque converter stall speed is slightly below specification: The engine may be low on power. See Engine Does Not Develop Full Power . (Group 9010-15.) The engine may not be attaining full fuel. See Low Pressure Fuel System Check and High Pressure Fuel System Check . (Group 9010-25.) Also see Engine Speed Too Low During Torque Converter Stall . (Group 9020-15.) [8] - If the torque converter stall speed is extremely low (about 30% lower than specifications): The engine may be severely down on power. See Engine Does Not Develop Full Power . (Group 9010-15.) The engine may not be attaining full fuel. See Low Pressure Fuel System Check and High Pressure Fuel System Check . (Group 9010-25.) The torque stator may be freewheeling. Perform Torque Converter Stator Tests . (Group 9020-25.) Also see Engine Speed Too Low During Torque Converter Stall . (Group 9020-15.) If engine stall speed is greater than specification: The transmission may have slipping clutches. Perform Transmission Pressure Test . (Group 9020-25.) Transmission oil level might be too low or high. See Check Transmission Oil Level . (Operator′s Manual.) The torque converter stator may be stuck. Perform Torque Converter Stator Tests . (Group 9020-25.) Also, see Engine Speed Too High During Torque Converter Stall . (Group 9020-15.)
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Section 9020 page 102
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Section 9020 - POWER TRAIN
Group 25: Tests
Torque Converter Stator Tests Specifications SPECIFICATIONS Freewheeling Stator Transmission Oil Temperature
80—90°C 176—194°F
Stuck Stator Transmission Oil Temperature
100°C 212°F
Transmission Oil Operating Temperature
80—90°C 176—194°F
Engine Speed—Fast Idle
2250 rpm
The torque converter stator test checks the torque converter for the following conditions: Freewheeling, when the stator clutch will not lock. Locked, when the stator clutch will not release. Freewheeling Stator Test—A freewheeling stator can cause sluggish slow speed operation, but machine will seem to operate normally at high speeds. Transmission oil will get hot or overheat quickly. Transmission may not upshift with engine at full speed. [1] - Operate loaded machine in a normal manner and monitor transmission temperature. [2] - While operating machine, notice how and when transmission upshifts. [3] - If transmission oil temperature is hotter than normal and transmission upshifts sluggishly or not at all, stator is freewheeling. Torque converter must be repaired. Item
Measurement
Specification
Freewheeling Stator Transmission Oil
Temperature
80—90°C 176—194°F
Stuck Stator Test—A stuck stator will cause transmission oil to overheat and not cool to normal temperature during nonoperation. Transmission will overheat at fast operating speeds. Machine may not reach full operating speeds. Torque converter stall test results will be normal. [1] - Warm transmission oil to operating temperature. Perform Transmission Warmup Procedure . (Group 9020-25.) Item
Measurement
Specification
Transmission Oil Operating
Temperature
80—90°C 176—194°F
[2] - Shift transmission to neutral and run engine at specification for 2 to 3 minutes. Monitor transmission temperature. Item
Measurement
Specification
Engine—Fast Idle
Speed
2250 rpm
If transmission temperature does not cool to normal operating temperature, stator may be stuck. Torque converter must be repaired. Item
Measurement
Specification
Stuck Stator Transmission Oil
Temperature
100°C 212°F
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Section 9020 page 103
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Torque Converter Lockup Test Specifications SPECIFICATIONS Engine Speed—Slow Idle
900 rpm
Transmission Oil Temperature
80—90°C 175—195°F
Torque Converter Lockup Pressure
13.5—14.5 bar 1350—1450 kPa 196—210 psi
Essential Tools ESSENTIAL TOOLS 202839 1/2 Quick Coupler x 7/16-20 ORB
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure/Temperature Analyzer JT02161 Transducer 3500 kPa (35 bar) (500 psi) JT02159 6.1 m (20 ft.) Cable with Couplers
Transmission Test Port Location LEGEND: 1 2 3 4 5 6 7 8 9 10 11 <- Go to Section TOC
Lube Pressure Test Port Torque Converter Lockup Test Port Clutch V Test Port Hydraulic System Pressure Test Port Clutch E Test Port Clutch G Test Port Clutch C Test Port Clutch F Test Port Clutch A Test Port Clutch R Test Port Clutch B Test Port Section 9020 page 104
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
12
Group 25: Tests
Clutch D Test Port
[1] CAUTION: Avoid personal injury from unexpected machine movement. Perform procedure in an open area away from other people and machines. With engine OFF, install 202839 Quick Coupler in torque converter lockup test port (2). 1/2 Quick Coupler x 7/16-20 ORB 202839 Installed in pressure port for testing equipment attachment. [2] - Attach JT02161 Transducer, JT02159 Cable with Couplers, and JT02158 Digital Pressure/Temperature Analyzer to quick coupler of pressure port to be tested. Transducer 3500 kPa (35 bar) (500 psi) JT02161 Connect to pressure port. 6.1 m (20 ft.) Cable with Couplers JT02159 Cable extension between transducer and digital pressure and temperature analyzer. Digital Pressure/Temperature Analyzer JT02158 To measure pressure. [3] - Start machine and warm up transmission to normal operating temperature. See Transmission Warmup Procedure . (Group 9020-25.) Item
Measurement
Specification
Transmission Oil Operating
Temperature
80—90°C 175—195°F
[4] - Operate the machine in an open area away from people or other machines. [5] - Hold transmission in 2nd gear by using gear hold or arrow down switch to 2nd gear on sealed switch module (SSM). See Sealed Switch Module (SSM) and see Shifting the Transmission . (Operator′s Manual.) [6] Drive the machine and increase engine speed so that lockup pressure increases and torque converter clutch lockup occurs. Record pressure and compare to specification. Item
Measurement
Specification
Converter Lockup
Pressure
13.5—14.5 bar 1350—1450 kPa 196—210 psi
If pressure is not present at lockup pressure port, check torque converter lockup solenoid (Y68) for proper operation. If pressure at lockup pressure port is to specification, check torque converter lockup clutch for proper operation. Transmission will overheat during operation if torque converter lockup clutch is not functioning properly.
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Section 9020 page 105
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Electronic Clutch Calibration Electronic clutch calibration should be performed under the following conditions: After replacing the transmission control unit (TCU). After overhauling the transmission. After replacing the transmission. After changing the transmission oil and/or transmission filters. →NOTE: When the TCU is placed into calibration mode, the method of exiting the calibration mode is a hard reset, turning ignition power OFF then ON. [1] - Enable service mode. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [2] - In the MAIN MENU, push NEXT button until DIAGNOSTICS menu is highlighted, then push SELECT button. [3] →NOTE: When the TCU is placed into calibration mode, the method of exiting the calibration mode is a hard reset, turning ignition power OFF, then ON. In the DIAGNOSTICS menu, enter CALIBRATIONS menu, then highlight and select TRANSMISSION calibrations. The CMU will display a screen stating: SUMP TEMP (82—95° C) XXX° C (displays actual transmission sump temperature) →NOTE: The cooling fan is cut off until transmission sump oil exceeds temperature of of 85°C (185°F) and torque converter output oil exceeds temperature of 110°C (230°F). [4] - If SUMP oil temperature is < 82°C (180°F), start machine and warm up transmission to normal operating temperature. See Transmission Warmup Procedure .(Group 9020-25.) [5] - When the transmission temperature is within specification, a check mark (✓) will appear, indicating transmission calibration can continue. [6] - Push SELECT button to initiate the transmission clutch calibration. [7] - The following conditions must be met to continue transmission clutch calibration: Transmission in neutral. →NOTE: Vehicle must not move, if the transmission output shaft rotates more than 180° the calibration will be aborted. Park brake engaged. Engine running. SUMP temperature> 85°C (185°F) A check mark (✓) will appear, indicating that each condition is met. [8] - When all conditions are met, push SELECT button to continue calibration. [9] →NOTE: Accelerator pedal must be pushed and held for the duration of calibration. Once the calibration becomes active, transmission sump temperature must not drop below 82° C or the calibration will be aborted. <- Go to Section TOC
Section 9020 page 106
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Section 9020 - POWER TRAIN
Group 25: Tests
A screen will appear, stating: HOLD ACCELERATOR TO CALIBRATE. Push and hold the accelerator to continue transmission calibrations. [10] →NOTE: The machine may jerk forward or backward during the transmission calibration. The transmission control unit (TCU) will then start to calibrate each transmission clutch. [11] - If the transmission calibration is aborted or fails, the only method of exiting the calibration mode is a hard reset, turning the ignition power OFF, then ON. [12] →NOTE: Continue to hold accelerator pedal down until the engine fully stops Push Engine Stop button on the SSM once CALIBRATION SUCCESSFUL appears on the screen [13] - Wait 5-10 seconds before restarting the engine
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Section 9020 page 107
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Service Brake Accumulator Pressure Regulator Valve Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature
60—71°C 140—160°F
Engine Speed (slow idle)
900 rpm
Service Brake Accumulator Pressure Reducing Valve X2 Pressure
19 000 kPa 190 bar 2756 psi
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure/Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02159 6.1 m (20 ft.) Cable with Couplers
The purpose of this test is to check the service brake accumulator pressure regulator valve X2 pressure setting and adjust as necessary. [1] CAUTION: Prevent possible injury from unexpected machine movement. Install articulation locking bar before working around frame hinge area. Install articulation locking bar. [2] - Perform Hydraulic System Warmup Procedure . (Group 9025-25.) Use CAN monitor unit to monitor hydraulic oil temperature. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Item
Measurement
Specification
Hydraulic Oil
Temperature
60—70°C 140—160°F
[3] →NOTE: The accuracy of this test and adjustment is dependent on the correct adjustment of the steering relief valve pressure. Perform Steering Relief Valve Pressure Test and Adjustment . (Group 9025-25.) [4] CAUTION: 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. With engine OFF, apply and release service brake pedal approximately 35—40 times to relieve pressure from service brake system. [5] <- Go to Section TOC
Section 9020 page 108
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
LEGEND: 1 Main Pump (PM) 2 Steering (OM) 3 Brake Charge (MP4) 4 Dump Body Pilot (PS) 5 Fan Drive Load Sense (LSFD) 6 Main Pump Load Sense (LSPM)
Test Port Manifold Connect JT02162 Transducer, JT02159 Cable with Couplers, and JT02158 Digital Pressure/Temperature Analyzer to brake charge (MP4) (3) of test port manifold. Transducer 35 000 kPa (350 bar) (5000 psi) JT02162 Installed into test port. Digital Pressure/Temperature Analyzer JT02158 To measure pressure. 6.1m (20 ft.) Cable with Couplers JT02159 Cable extension between transducer and digital pressure and temperature analyzer. [6] - Activate Service Mode. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [7] - Run engine at specification. Item
Measurement
Specification
Engine
Speed (slow idle)
900 rpm
[8] CAUTION: Beware of rotating drive shaft when making adjustment on main hydraulic pump. Keep all tools and equipment stored away from openings so they do not fall into the drive shaft. To avoid personal injury, wear close-fitting clothing. IMPORTANT: Avoid damage to machine frame. Do not steer machine back and forth with articulation lock bar in place. →NOTE: If pressure reading was above specification, the excess pressure must be released before pressure is set. Push on service brake pedal repeatedly until pressure is below specification.
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Section 9020 page 109
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Hydraulic System Manifold (top view) LEGEND: 7 Service Brake Accumulator Pressure Regulator Valve X2 Turn steering wheel to the left against articulation locking bar and hold. Take reading at this time. If pressure is not to specification, adjust service brake accumulator pressure regulator valve X2 (7) on the hydraulic system manifold as follows: Item
Measurement
Specification
Service Brake Accumulator Pressure Reducing Valve X2
Pressure
19 000 kPa 190 bar 2756 psi
a. Loosen adjusting screw lock nut on service brake accumulator pressure regulator valve X2 (7). b. Turn adjusting screw in to increase pressure or out to decrease pressure. c. Tighten adjusting screw lock nut on service brake accumulator pressure regulator valve X2 (7). If service brake accumulator pressure reducing valve cannot be adjusted to specification, replace valve and repeat test.
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Section 9020 page 110
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Service Brake Accumulator Charge Valve Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature
60—71°C 140—160°F
Engine Speed (slow idle)
900 rpm
Service Brake Accumulator Circuit Charge Pressure
16 500 kPa 165 bar 2393 psi
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure/Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02159 6.1 m (20 ft.) Cable with Couplers
The purpose of this test is to check the service brake accumulator charge valve X3 pressure setting and adjust as necessary. [1] CAUTION: Prevent possible injury from unexpected machine movement. Install articulation locking bar before working around frame hinge area. Install articulation locking bar. [2] →NOTE: The accuracy of this test and adjustment is dependent on the correct adjustment of the main hydraulic pump. Perform Main Hydraulic Pump Margin and Maximum Pressure Test and Adjustment . (Group 9025-25.) [3] CAUTION: 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. With engine OFF, apply and release service brake pedal approximately 35—40 times to relieve pressure from service brake system. [4] -
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Section 9020 page 111
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
LEGEND: 1 Main Pump (PM) 2 Steering (OM) 3 Brake Charge (MP4) 4 Dump Body Pilot (PS) 5 Fan Drive Load Sense (LSFD) 6 Main Pump Load Sense (LSPM)
Test Port Manifold Connect JT02162 Transducer, JT02159 Cable with Couplers, and JT02158 Digital Pressure/Temperature Analyzer to brake charge MP4 (3) of test port manifold. Transducer 35 000 kPa (350 bar) (5000 psi) JT02162 Installed into test port. Digital Pressure/Temperature Analyzer JT02158 To measure pressure. 6.1 m (20 ft.) Cable with Couplers JT02159 Cable extension between transducer and digital pressure and temperature analyzer. [5] - Activate Service Mode. See CAN Monitor Unit (CMU)-Service Mode . (Group 9015-16.) [6] - Perform Hydraulic System Warmup Procedure . (Group 9025-25.) Use CAN monitor unit (CMU) to monitor hydraulic oil temperature. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Item
Measurement
Specification
Hydraulic Oil
Temperature
60—70°C 140—160°F
[7] - Run engine at specification. Item
Measurement
Specification
Engine
Speed (slow idle)
900 rpm
[8] →NOTE: Main hydraulic pump will go into stroke and charge pressure will start to rise at approximately 13 000 kPa (130 bar) (1886 psi). This pressure cannot be adjusted. Accumulators must be discharged and main hydraulic pump allowed to go into stroke after each adjustment to obtain an accurate reading.
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Section 9020 page 112
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Section 9020 - POWER TRAIN
Group 25: Tests
LEGEND: 7 Service Brake Accumulator Charge Valve X3
Hydraulic System Manifold Actuate service brake pedal repeatedly until main hydraulic pump goes into stroke to charge service brake accumulators. The pressure will rise until service brake accumulators are fully charged. Take pressure reading at this time. If pressure is not to specification, adjust service brake accumulator charge valve X3 (7) on hydraulic system manifold as follows: Item
Measurement
Specification
Service Brake Accumulator Circuit Charge
Pressure
16 500 kPa 165 bar 2393 psi
a. Loosen adjusting screw lock nut on service brake accumulator charge valve X3 (7). b. Turn adjusting screw in to increase pressure or out to decrease pressure. c. Tighten adjusting screw lock nut on service brake accumulator charge valve X3 (7). [9] - Cycle ignition to exit Service Mode. If service brake accumulator charge valve cannot be adjusted to specification, replace valve and repeat test.
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Section 9020 page 113
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Service Brake Low Pressure Switch and Service Brake Accumulator Charge Test Specifications SPECIFICATIONS Hydraulic Oil Temperature
60—71° C 140—160° F
Service Brake Low Pressure Switch Actuation Pressure
11 597—12 700 kPa 116—127 bar 1682—1842 psi
Service Brake Accumulator Gas Charge Pressure
8000 kPa 80 bar 1160 psi
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure/Temperature Analyzer JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02159 6.1 m (20 ft.) Cable with Couplers
Hydraulic System Manifold LEGEND: 1 Brake Accumulator Pressure Test Port (S4) 2 Service Brake Accumulator Charge Orifice 3 Brake Accumulator Low Pressure Switch (B35) The purpose of this test is to check the operation of brake accumulator low pressure switch (B35) (3) and to check the gas charge pressure of the service brake accumulator. <- Go to Section TOC
Section 9020 page 114
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
[1] CAUTION: Prevent possible injury from unexpected machine movement. Install articulation locking bar before working around frame hinge area. Install articulation locking bar. [2] CAUTION: 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. With engine OFF, apply and release service brake pedal approximately 35—40 times to relieve pressure from system. [3] - Connect JT02162 Transducer, JT02159 Cable with Couplers, and JT02158 Digital Pressure/Temperature Analyzer to brake accumulator pressure test port (S4) (1) of hydraulic system manifold. Transducer 35 000 kPa (350 bar) (5000 psi) JT02162 Installed into test port. Digital Pressure/Temperature Analyzer JT02158 To measure pressure. 6.1 m (20 ft.) Cable with Couplers JT02159 Cable extension between transducer and digital pressure/temperature analyzer. [4] - Perform Hydraulic System Warmup Procedure . (Group 9025-25.) Use CAN monitor unit (CMU) to monitor hydraulic oil temperature. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Item
Measurement
Specification
Hydraulic Oil
Temperature
60—71°C 140—160°F
[5] - Stop engine. [6] - Push engine start switch on sealed switch module (SSM) once for less than 0.5 second; do not start engine. [7] →NOTE: Machine software prevents service brake low pressure indicator from displaying because engine is not running. Other indicator LEDs may be on or flashing, but buzzer will not sound because engine is not running. Check the status of brake accumulator low pressure switch (B35) (3) using the monitor by accessing the MAIN MENU / DIAGNOSTICS / READINGS/ CCU / INPUT SWITCHES submenu in the CMU menu structure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) [8] - Replace brake accumulator low pressure switch B35 (3) if switch status on monitor does not change at specification. Item
Measurement
Specification
Service Brake Low Pressure Switch Actuation
Pressure
11 597—12 700 kPa
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Section 9020 page 115
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN Item
Group 25: Tests Measurement
Specification 116—127 bar 1682—1842 psi
[9] - If switch status on monitor does not change at specification, replace brake accumulator low pressure switch (B35) (3). [10] - Continue applying and releasing service brake pedal until the decreasing pressure reading drops considerably. The point at which pressure drops is the gas charge pressure of service brake accumulator charge orifice (2). Item
Measurement
Specification
Service Brake Accumulator Gas Charge
Pressure
8000 kPa 80 bar 1160 psi
If service brake accumulator gas charge pressure is not to specification, charge the service brake accumulator. see Front and Rear Service Brake Accumulators Pressure Test and Charge Procedure . (Group 9025-25.)
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Section 9020 page 116
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Front and Rear Service Brake Accumulators Pressure Test and Charge Procedure Specifications SPECIFICATIONS 8000 kPa 80 bar 1160 psi
Service Brake Accumulator Charge Pressure
Essential Tools ESSENTIAL TOOLS JT05711 High Pressure Nitrogen Accumulator Charging Regulator JT05420 Nitrogen Accumulator Charging Kit JT01735 Gas Cock
The purpose of this test is to measure the dry nitrogen charge pressure in each individual front and rear service brake accumulator and charge with additional dry nitrogen if necessary. CAUTION: Prevent possible injury from high pressure fluid. Relieve oil pressure from accumulators before servicing components. Hydraulic oil in accumulators can be stored at pressures equal to or above system relief pressures. [1] - Apply and release brake pedal approximately 35—40 times to relieve pressure from system. [2] - Remove accumulator charge valve guard and cap. [3] IMPORTANT: Only dry nitrogen should be used to charge accumulators. Do not use compressed air or any combustible gas as these will cause oxidation and condensation in the accumulator. Close valve on dry nitrogen container and install JT05711 High Pressure Nitrogen Accumulator Charging Regulator. Turn Thandle on regulator out until no resistance is felt. Open valve on dry nitrogen container. There should be no dry nitrogen escaping from regulator. If there is, turn T-handle out until it stops. High Pressure Nitrogen Accumulator Charging Regulator JT05711 Used to charge front and rear service brake accumulators. [4] - Connect JT05420 Nitrogen Accumulator Charging Kit with JT01735 Gas Cock to charging regulator. Nitrogen Accumulator Charging Kit JT05420 Used to charge front and rear service brake accumulators. Gas Cock JT01735 Used to charge front and rear service brake accumulators. [5] CAUTION: Prevent possible injury from high pressure gas. Turn T-handle on JT01735 Gas Cock fully out, before installing gas cock to accumulator charge valve. <- Go to Section TOC
Section 9020 page 117
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Section 9020 - POWER TRAIN
Group 25: Tests
Accumulator Charge Valve (rear accumulators shown) LEGEND: 1 Accumulator Charge Valve Connect gas cock to the accumulator charge valve (1). [6] IMPORTANT: Do not turn gas cock T-handle in fully. Damage to charge valve core will occur. Close regulator bleed valve and turn gas cock T-handle in until accumulator pressure shows on gauge. [7] →NOTE: After charging an accumulator, allow gas temperature to stabilize for 10 to 15 minutes, before recording charge pressure again. Record accumulator charge pressure. Charge accumulator to specification if necessary. Turn regulator T-handle in to increase pressure to specification. If charge pressure is beyond specification, release pressure by slowly opening bleed valve until pressure is to specification. Item
Measurement
Specification
Service Brake Accumulator Charge
Pressure
8000 kPa 80 bar 1160 psi
[8] - Turn gas cock T-handle out. Close valve on dry nitrogen container. Slowly open bleed valve until both regulator gauges return to zero. Turn regulator T-handle out. [9] - Remove gas cock from accumulator charge valve. [10] - Install charge valve cap and guard. [11] - Apply and release brake pedal approximately 3—4 times to relieve any pressure buildup in system. [12] →NOTE: The service brake accumulators internal components are not serviceable. If an accumulator will not charge to specification, replace the accumulator. Repeat procedure for each accumulator. <- Go to Section TOC
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Section 9020 - POWER TRAIN
Group 25: Tests
If an accumulator will not charge to specification, replace accumulator. See Brake Accumulator Remove and Install . (Group 1060.)
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Section 9020 page 119
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Section 9020 - POWER TRAIN
Group 25: Tests
Service Brake Valve Test Specifications SPECIFICATIONS Hydraulic Oil Temperature
60—71°C 140—160°F
Engine Speed (slow idle)
900 rpm
Full Service Brake Pedal Travel Pressure
8963—9653 kPa 90—97 bar 1300—1400 psi
Service Brake Pedal Released Pressure
70 kPa 0.70 bar 10 psi or less
The purpose of this test is to check operation of the service brake valve and record service brake pressures at full service brake pedal travel and with service brake pedal released. To accurately diagnose the service brake functionality for excessive wear, the service brake system needs to be isolated from the electronic brake valve (EBV). If excessive brake wear is present, it may also be necessary to check the EBV operation. See Electronic Brake Valve (EBV) Test . (Group 9020-25.) For more information on the service brake system operation, see Service Brake System Operation . (Group 9020-05.) [1] CAUTION: Prevent personal injury from unexpected machine movement. Always install articulation locking bar before working in the articulation joint area. Install articulation locking bar. [2] CAUTION: 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. With engine OFF, apply and release service brake pedal approximately 35—40 times to relieve pressure from service brake system. [3] →NOTE: The service brake valve consists of two separate sections. The front section provides oil for the rear service brakes, while the rear section provides oil for the front service brakes. Each section needs to be tested separately.
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Section 9020 page 120
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Section 9020 - POWER TRAIN
Group 25: Tests
LEGEND: 1 Pressure Gauge 2 Brake Line Tee 3 11/16-16 ORFS Tee Fitting
Middle Axle Service Brake Port—Middle Axle Shown Disconnect hydraulic brake line at the brake line tee (2) and install 11/16-16 ORFS tee fitting (3). Connect pressure gauge (1) to fitting. [4] LEGEND: 4 Electronic Brake Valve-to-Service Brake Valve Line 5 Electronic Brake valve (EBV)
Electronic Brake Valve (EBV) Disconnect the electronic brake valve-to-service brake valve line (4) from the electronic brake valve (EBV) (5) and install caps on line and valve. [5] - Perform Hydraulic System Warmup Procedure . (Group 9025-25.) Use CAN monitor unit to monitor hydraulic oil temperature. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Item
Measurement
Specification
Hydraulic Oil
Temperature
60—70°C 140—160°F
[6] - Run engine at specified speed. Item
Measurement
Specification
Engine Speed (slow idle)
Speed
900 rpm
[7] IMPORTANT: Service brake pressure must decrease to 70 kPa (0.70 bar) (10 psi) or less after service brake pedal release to prevent excessive drag, which causes premature wear to service brake pads and disks. →NOTE: Pressure should slowly increase as service brake pedal is depressed. As the service brake pedal nears the end of its travel, the service brake pressure will suddenly go to specification pressure. While observing pressure reading, slowly depress service brake pedal to the end of its travel and then slowly release the service brake pedal. Record pressure reading at end of service brake pedal travel and after service brake pedal is released. The pressure must increase gradually and reach specification at full service brake pedal travel and gradually decrease to <- Go to Section TOC
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Group 25: Tests
specification upon service brake pedal release. Item
Measurement
Specification
Full Service Brake Pedal Travel
Pressure
8963—9653 kPa 90—97 bar 1300—1400 psi
Service Brake Pedal Released
Pressure
70 kPa 0.70 bar 10 psi or less
[8] - Repeat procedure for remaining axle. [9] - When the test is complete, stop the engine. Remove all caps and plugs and connect all lines. [10] CAUTION: Avoid personal injury or damage to machine from a sudden loss of brake functionality. Air in the brake system will significantly reduce brake pressure. Bleed service brakes after performing this test. Bleed service brake. See Bleed Service Brake . (Group 1060.) If pressure is not to specification with service brake pedal depressed, see the following: See Service Brake Accumulator Pressure Reducing Valve Test and Adjustment . (Group 9020-25.) See Front and Rear Service Brake Accumulators Pressure Test and Charge Procedure . (Group 9020-25.) If pressure does not increase or decrease gradually as service brake pedal is depressed and released, check for kinked or restricted lines to affected axle. Inspect service brake valve and replace if necessary, see Brake Valve Remove and Install . (Group 1060.)
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Section 9020 page 122
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Electronic Brake Valve (EBV) Test Specifications SPECIFICATIONS Hydraulic Oil Temperature
60—71°C 140—160°F
Engine Speed
900 rpm
Electronic Brake Valve Pressure—Applied
13 000—16 650 kPa 130—165 bar 1885—2393 psi
Electronic Brake Valve Pressure—Released
70 kPa 0.70 bar 10 psi or less
Essential Tools ESSENTIAL TOOLS 11/16-16 ORFS Tee Fitting JT02156A Digital Pressure/Temperature Analyzer and Transducer JT03482 High Pressure Test Hose Kit, to tee fitting
The purpose of this test is to check operation of the electronic brake valve (EBV) and record brake pressures at full valve travel and with brake valve released. [1] CAUTION: Prevent personal injury from unexpected machine movement. Always install articulation locking bar before working in the articulation joint area. Install articulation locking bar. [2] CAUTION: 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. With engine OFF, apply and release the brake pedal approximately 35—40 times to relieve pressure from service brake system. [3] LEGEND: 1 Electronic Brake Valve-to-Service Brake Valve Line 2 Electronic Brake Valve
Electronic Brake Valve (EBV) Disconnect electronic brake valve-to-service brake valve line (1) at the electronic brake valve (2) and install 11/16-16 ORFS tee fitting. <- Go to Section TOC
Section 9020 page 123
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Section 9020 - POWER TRAIN
Group 25: Tests
[4] - Connect JT02156A Digital Pressure/Temperature Analyzer and Transducer or a gauge, using JT03482 High Pressure Test Hose Kit, to tee fitting. High Pressure Test Hose Kit JT03482 To connect transducer or gauge to test port manifold. Digital Pressure/Temperature Analyzer JT02156A To read hydraulic pressure. [5] - Perform Hydraulic System Warmup Procedure . (Group 9025-25.) Item
Measurement
Specification
Hydraulic Oil
Temperature
60—70°C 140—160°F
[6] - While observing pressure reading, momentarily energize electronic brake with an external power source. See Cab Harness (W3) Wiring Diagram . (Group 9015-15.) Record pressure readings while the electronic brake valve is applied and released. Compare readings to specification. Item
Measurement
Specification
Electronic Brake Valve—Applied
Pressure
13 000—16 650 kPa 130—165 bar 1885—2393 psi
Electronic Brake Valve—Released
Pressure
70 kPa 0.70 bar 10 psi or less
[7] - When the test is completed, stop the engine. Remove fittings and connect the electronic brake valve line to electronic brake valve. CAUTION: Avoid personal injury or damage to machine from a sudden loss of brake functionality. Air in brake system will significantly reduce brake pressure. Bleed service brakes after performing this test. [8] - Bleed service brake. See Bleed Service Brake . (Group 1060.) If pressure does not increase or decrease gradually as electronic brake valve is energized and released, check for kinked or restricted lines to affected axle. Inspect service electronic brake valve; repair or replace as needed.
<- Go to Section TOC
Section 9020 page 124
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Axle Cooling Pump Pressure Test and Flow Test Specifications SPECIFICATIONS Axle Oil Temperature
49°C 120°F
Hydraulic Oil Temperature
60—70°C 140—160°F
Engine—Fast Idle Speed
2250 rpm
Engine—Slow Idle Speed
900 rpm
Front Axle Lube Pressure (minimum)
276 kPa 2.76 bar 40 psi
Front Axle Circulation Pump Flow Rate (approximate) (slow idle speed)
23 L/min 6 gpm
Front Axle Circulation Pump Flow Rate (approximate) (fast idle speed)
57 L/min 15 gpm
Middle Axle Lube Pressure (minimum)
276 kPa 2.76 bar 40 psi
Middle Axle Circulation Pump Flow Rate (approximate)
45 L/min 12 gpm
Rear Axle Lube Pressure (minimum)
276 kPa 2.76 bar 40 psi
Essential Tools ESSENTIAL TOOLS JT07148 Digital Hydraulic Flowmeter
The purpose of this test is to verify that there is no restriction in the axle cooling circuits and that the axle circulation pumps are functioning properly to keep axle oil temperatures within normal operating range. [1] - Drive machine to warm axle oil to normal operating temperature. Item
Measurement
Specification
Axle Oil
Temperature
49°C 120°F
[2] - Park and Prepare for Service Safely . (Group 9000-01.) [3] CAUTION: Avoid personal injury. Machine may roll when park brake is released. Use chocks in front of and behind wheels. Install wheel chocks in front and behind wheels. [4] - Check front, middle, and rear axle oil levels. See Check Axle Oil Levels . (Operator′s Manual.) [5] - Check axle cooling pumps for leaks prior to performing axle cooling pump pressure and flow test. [6] - Perform Hydraulic System Warmup Procedure . (Group 9025-25.) Use CAN monitor unit to monitor hydraulic oil temperature. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Item
Measurement
Specification
Hydraulic Oil
Temperature
60—70°C 140—160°F
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Section 9020 page 125
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
[7] - Front Axle Cooling Pump— With engine running, activate service mode. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [8] - Go to Diagnostics/Readings/CCU/Input Sensors/FNT Axle Lube. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) [9] - Operate engine at specification. Item
Measurement
Specification
Engine—Fast Idle
Speed
2250 rpm
[10] LEGEND: 1 Front Axle Cooler Line 2 Front Axle Cooler Manifold
Front Axle Cooler Manifold Record front axle lube pressure and compare to specifications. Item
Measurement
Specification
Front Axle Lube
Pressure (minimum)
276 kPa 2.76 bar 40 psi
[11] - Remove the front axle cooler line (1) from the front axle cooler manifold (2) and install JT07148 Digital Hydraulic Flowmeter inline with the front axle cooler circuit. Digital Hydraulic Flowmeter JT07148 To measure hydraulic fluid flow. [12] - Operate engine at slow idle. Record flow and compare to specification. Item
Measurement
Specification
Engine—Slow Idle
Speed
900 rpm
Front Axle Circulation Pump
Flow Rate (approximate)
23 L/min 6 gpm
[13] - Operate engine at fast idle. Record flow and compare to specification. Item
Measurement
Specification
Engine—Fast Idle
Speed
2250 rpm
Front Axle Circulation Pump
Flow Rate (approximate)
57 L/min 15 gpm
[14] - Middle Axle Cooling Pump— With engine running, activate service mode. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [15] →NOTE: Enabling CDL Pressure through Service Mode removes power from axle cooling cut-off solenoid (Y2), enabling oil flow to the rear axles. Go to Diagnostics/Calibrations/Hydraulics and select Set CDL Pressure. See CAN Monitor Unit (CMU)—Calibrations . (Group 9015-16.) <- Go to Section TOC
Section 9020 page 126
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
[16] - Go to Diagnostics/Readings/CCU/Input Sensors/MID Axle Lube. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) [17] - Record middle axle lube pressure and compare to specifications. Item
Measurement
Specification
Middle Axle Lube
Pressure (minimum)
276 kPa 2.76 bar 40 psi
[18] LEGEND: 3
Middle Axle Cooler Line
Middle Axle Cooler Line Remove the middle axle cooler line (3) located on the back side of the cab and install JT07148 Digital Hydraulic Flowmeter inline with the middle axle cooling circuit. See Hydraulic System Component Location . (Group 9025-15.) Digital Hydraulic Flowmeter JT07148 To measure hydraulic fluid flow. [19] - Operate engine at specification. Record flow and compare to specification. Item
Measurement
Specification
Engine—Fast Idle
Speed
2250 rpm
Middle Axle Circulation Pump
Flow Rate (approximate)
45 L/min 12 gpm
[20] - Go to Diagnostics/Calibrations/Hydraulics and select Normal. See CAN Monitor Unit (CMU)—Calibrations . (Group 9015-16.) [21] - Rear Axle Cooling Pump— With engine running, activate service mode. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [22] →NOTE: Enabling CDL Pressure through Service Mode removes power from axle cooling cut-off solenoid (Y2), enabling oil flow to the rear axles. Go to Diagnostics/Calibrations/Hydraulics and select Set CDL Pressure. See CAN Monitor Unit (CMU)—Calibrations . (Group 9015-16.) [23] - Go to Diagnostics/Readings/CCU/Input Sensors/Rear Axle Lube. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) [24] - Record rear axle lube pressure and compare to specifications. Item
Measurement
Specification
Rear Axle Lube
Pressure (minimum)
276 kPa 2.76 bar 40 psi
[25] - Go to Diagnostics/Calibrations/Hydraulics and select Normal. See CAN Monitor Unit (CMU)—Calibrations . (Group <- Go to Section TOC
Section 9020 page 127
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
9015-16.) [26] - Remove test equipment and cycle ignition to exit Service Mode. If pressure is not to specification check for: Kinked or restricted lines to affected cooler. Differential gear case oil suction screen for debris. See Differential Gear Case Assembly — Assembly . (CTM115319.) Axle oil level. See Check Axle Oil Levels . (Operator’s Manual.) Axle oil filter restriction. See Hydraulic System Component Location . (Group 9025-15.) and see Replace Axle Oil Filters . (Operator′s Manual.) Axle cooling pump malfunction.
Park Brake Test Specifications SPECIFICATIONS Engine Speed
1000 rpm
CAUTION: To prevent personal injury, perform test in an open area away from people and other machines. Machine may move unexpectedly during this test. [1] - Apply service brake and release park brake. [2] - Apply inter-axle differential lock (IDL) to prevent wheel slippage. [3] - Push F (forward) on sealed switch module (SSM). [4] - Apply park brake and release service brake. [5] - Increase engine speed to fast idle for 5 seconds. Item
Measurement
Specification
Engine
Speed
1000 rpm
[6] - Park brake must prevent machine movement. If machine moves, check park brake pad thickness and park brake adjustment. See Park Brake Pad Thickness Check and see Park Brake Adjustment . (Group 9020-25.)
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Section 9020 page 128
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Park Brake Pressure Test Specifications SPECIFICATIONS Park Brake Pressure Park Brake Applied
0 kPa 0 bar 0 psi
Park Brake Released (Approximate)
15 500 kPa 155 bar 2240 psi
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure/Temperature Analyzer JT02159 6.1 m (20 ft.) Cable with Couplers JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
[1] - Perform Park and Prepare for Service Safely . (Group 9000-01.) CAUTION: 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. [2] -
Park Brake Test LEGEND: 1 Park Brake Hydraulic Line Disconnect park brake hydraulic line (1) from park brake actuator and install JT02158 Digital Pressure/Temperature Analyzer to fitting using JT02159 6.1 m (20 ft.) Cable with Couplers, and JT02162 Transducer 35 000 kPa (350 bar) (5000 psi). Digital Pressure/Temperature Analyzer <- Go to Section TOC
Section 9020 page 129
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
JT02158 Used to check hydraulic pressure and temperature. Transducer 35 000 kPa (350 bar) (5000 psi) JT02162 Used to check hydraulic pressure and temperature. JT02159 6.1 m (20 ft.) Cable with Couplers JT02159 Used to check hydraulic pressure and temperature. [3] - Start engine and observe pressure reading on gauge with park brake engaged. Record and compare readings to specification. Item
Measurement
Specification
Park Brake Applied
Pressure
0 kPa 0 bar 0 psi
[4] - With engine running, apply service brake and release park brake. Record and compare readings to specification. Item
Measurement
Specification
Park Brake Released
Pressure (approximate)
15 500 kPa 155 bar 2240 psi
If park brake pressure is not to specification, see Park Brake Does Not Release . (Group 9020-15.)
Park Brake Pad Thickness Check
Park Brake Pad Minimum Thickness Specifications SPECIFICATIONS 3 mm 0.118 in.
Park Brake Pad Minimum Thickness
CAUTION: Always install articulation locking bar and dump body locking bar when working under the raised dump body. Personal injury may result if the dump body lowers unexpectedly. [1] - Install articulation locking bar, raise dump body, and install dump body locking bar. See Install Articulation Locking Bar and see Install Dump Body Locking Bar . (Operator′s Manual.) [2] - Measure park brake pad thickness. <- Go to Section TOC
Section 9020 page 130
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Item
Measurement
Specification
Park Brake Pad Minimum
Thickness
3 mm 0.118 in.
Change park brake pads when they are less than specification. See Park Brake Pads Remove and Install . (Group 1111.)
Park Brake Adjustment [1] CAUTION: Avoid personal injury. Machine may roll when park brake is released. Use chocks in front of and behind wheels. Park machine on a level surface. Install chocks in front of and behind wheels. [2] CAUTION: Always install the dump body locking bar when working under the raised dump body. Personal injury may result if the dump body lowers unexpectedly. Raise dump body and install dump body locking bar. See Install Dump Body Locking Bar . (Operator′s Manual.) [3] LEGEND: 1
Adjusting Nut
Adjusting Park Brake Turn adjusting nut (1) counterclockwise until resistance is felt. →NOTE: A clicking sound is heard as adjusting nut is turned. [4] - Turn adjusting nut (1) clockwise until resistance is felt. [5] - Stop turning. [6] - Turn adjusting nut (1) counterclockwise seven clicks. [7] - Release and apply park brake 20 times to help seat parts.
<- Go to Section TOC
Section 9020 page 131
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Strut Accumulator Pressure Test and Charge Procedure Specifications SPECIFICATIONS 3896—4309 kPa 39.0—43.1 bar 565—625 psi
Strut Accumulator Precharge Pressure
Essential Tools ESSENTIAL TOOLS JT05711 High Pressure Nitrogen Accumulator Charging Regulator JT05420 Nitrogen Accumulator Charging Kit JT01735 Gas Cock
The purpose of this test is to measure the dry nitrogen charge pressure in each strut accumulator and charge with additional dry nitrogen if necessary. [1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 9000-01.) [2] →NOTE: Strut lowering switch is located in the engine service compartment. Open front grille. [3] →NOTE: Front struts will automatically rise to operating height when the machine is driven faster than 3 km/h (2 mph).
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Section 9020 page 132
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Strut Lowering Switch Location LEGEND: 5 Strut Lowering Switch Push and hold strut lowering switch (5) until front of machine is fully lowered. Hold an additional 10 seconds to ensure accumulator is fully depleted. [4] -
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Section 9020 page 133
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Strut Accumulator Charge Valve (right strut accumulator shown) LEGEND: 1 Strut Accumulator 2 Front Suspension Stut 3 Strut Accumulator Charge Valve Remove valve cap from strut accumulator charge valve (3). [5] IMPORTANT: Only dry nitrogen should be used to charge accumulator. Do not use compressed air or any combustible gas as these will cause oxidation and condensation in the accumulator. Close valve on dry nitrogen container and install JT05711 High Pressure Nitrogen Accumulator Charging Regulator. Turn Thandle on regulator out until no resistance is felt. Open valve on dry nitrogen container. There should be no dry nitrogen escaping from regulator. If there is, turn T-handle out until it stops. High Pressure Nitrogen Accumulator Charging Regulator JT05711 Used to charge strut accumulator. [6] - Connect JT05420 Nitrogen Accumulator Charging Kit with JT01735 Gas Cock to charging regulator. Nitrogen Accumulator Charging Kit JT05420 Used to charge strut accumulator. Gas Cock JT01735 <- Go to Section TOC
Section 9020 page 134
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Used to charge strut accumulator. [7] CAUTION: Prevent possible injury from high pressure gas. Turn T-handle on JT01735 Gas Cock fully out, before installing gas cock to accumulator charge valve. Connect gas cock to strut accumulator charge valve (3). [8] IMPORTANT: Do not turn gas cock T-handle in fully. Damage to charge valve core will occur. Close regulator bleed valve and turn gas cock T-handle in until accumulator pressure shows on gauge. [9] →NOTE: After charging an accumulator, allow gas temperature to stabilize for 10 to 15 minutes, before recording charge pressure again. Record accumulator charge pressure. Charge accumulator to specification if necessary. Turn regulator T-handle in to increase pressure to specification. If charge pressure is beyond specification, release pressure by slowly opening bleed valve until pressure is to specification. Item
Measurement
Specification
Strut Accumulator Precharge
Pressure
3896—4309 kPa 39.0—43.1 bar 565—625 psi
[10] - Turn gas cock T-handle out. Close valve on dry nitrogen container. Slowly open bleed valve until both regulator gauges return to zero. Turn regulator T-handle out. [11] - Remove gas cock from accumulator charge valve. [12] - Install accumulator charge valve cap. [13] - Repeat procedure on other strut accumulator. [14] →NOTE: The strut accumulator internal components are not serviceable. If accumulator will not charge to specification, replace accumulator. See Strut Accumulator Remove and Install . (Group 0260.)
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Section 9020 page 135
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Cross-Axle Differential Lock (CDL) Pressure Test and Adjustment For Machines With (S.N. —668586) Specifications SPECIFICATIONS Axle Oil Temperature
49°C 120°F
Engine—Slow Idle Speed
900 rpm
Engine—Fast Idle Speed
2250 rpm
Cross Differential Lock Pressure—Axle Cooling Manifold Pressure
2758—2896 kPa 28—29 bar 400—420 psi
Cross-Axle Differential Pressure—Axle Differential Pressure Reducing Valve Pressure
2758—2896 kPa 28—29 bar 400—420 psi
[1] - Drive machine to warm axle oil to normal operating temperature. Item
Measurement
Specification
Axle Oil
Temperature
49°C 120°F
[2] - Park and Prepare for Service Safely . (Group 9000-01.) [3] CAUTION: Avoid personal injury. Machine may roll when park brake is released. Use chocks in front of and behind wheels. Install wheel chocks in front of and behind wheels. [4] - Middle and Rear Axle Differential Pressure— Activate Service Mode. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [5] - Go to Diagnostics/Calibrations/Hydraulic. Select Set CDL Pressure. [6] - Go to Diagnostics/Readings/CCU/Input Sensors. Select Middle CDL Pressure or Rear CDL Pressure depending on the axle that is being tested. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) [7] - Run engine at specification. Item
Measurement
Specification
Engine—Slow Idle
Speed
900 rpm
[8] →NOTE: The front, middle, and rear axle need to be tested and adjusted independently of one another, for the differential manifold location of each axle, see Hydraulic System Component Location . (Group 9025-15.)
<- Go to Section TOC
Section 9020 page 136
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
LEGEND: 1 Cross-Axle Differential Pressure Valve RV
Cross-Axle Differential Pressure Valve RV Engage the cross-axle differential lock. See Using Differential Lock . (Operator’s Manual.) Record reading. If pressure is not to specification, adjust cross axle differential pressure valve RV (1) on the appropriate axle cooling manifold as follows: Item
Measurement
Specification
Cross Differential Lock Pressure—Axle Cooling Manifold
Pressure
2758—2896 kPa 28—29 bar 400—420 psi
a. Loosen adjusting screw lock nut on cross-axle differential pressure valve RV (1). b. Turn adjusting screw in to increase pressure or out to decrease pressure. c. Tighten adjusting screw lock nut on cross-axle differential pressure valve RV (1). [9] - Cycle ignition to exit Service Mode. [10] - Front Axle Differential Pressure— Activate Service Mode. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [11] - Go to Diagnostics/Readings/CCU/Input Sensors. Select Front CDL Pressure. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) [12] →NOTE: The front axle differential pressure will vary depending on engine rpm. Verify proper engine speed is obtained while performing the following procedure. Incorrect engine rpm will result in inaccurate data. Run engine at specification. Item
Measurement
Specification
Engine—Slow Idle
Speed
900 rpm
[13] →NOTE: The front, middle, and rear axle need to be tested and adjusted independently of one another, for the differential manifold location of each axle, see Hydraulic System Component Location . (Group 9025-15.) Engage the cross-axle differential lock. See Using Differential Lock . (Operator’s Manual.) Record reading. If pressure is not to specification, adjust cross axle differential pressure valve RV (1) as follows: Item
Measurement
Specification
Cross Differential Lock Pressure—Axle Cooling Manifold
Pressure
2758—2896 kPa 28—29 bar 400—420 psi
a. Loosen adjusting screw lock nut on cross-axle differential pressure valve RV (1). <- Go to Section TOC
Section 9020 page 137
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
b. Turn adjusting screw in to increase pressure or out to decrease pressure. c. Tighten adjusting screw lock nut on cross-axle differential pressure valve RV (1). [14] -
Differential Lock Pressure Reducing Valve LEGEND: 2 Differential Lock Pressure Reducing Valve Block 3 Differential Lock Pressure Reducing Valve 4 Test Port Connect pressure transducer to test port (4) on differential lock pressure reducing valve block (2) on front axle. See Hydraulic System Component Location . (Group 9025-15.) [15] - Run engine at specification. Item
Measurement
Specification
Engine—Fast Idle
Speed
2250 rpm
[16] - Engage the cross-axle differential lock. See Using Differential Lock . (Operator’s Manual.) Record reading. If pressure is not to specification, adjust cross-axle differential pressure reducing valve (3) as follows: Item
Measurement Specification
Cross-Axle Differential Pressure—Axle Differential Pressure Reducing Valve
Pressure
2758—2896 kPa 28—29 bar 400—420 psi
a. Loosen adjusting screw lock nut on cross-axle differential pressure reducing valve (3). b. Turn adjusting screw in to increase pressure or out to decrease pressure. c. Tighten adjusting screw lock nut on cross-axle differential pressure reducing valve (3). [17] - Remove pressure transducer and cycle ignition to exit Service Mode. If pressure is not to specification, check for kinked or restricted lines or replace pumps.
For Machines With (S.N. 668587— )
<- Go to Section TOC
Section 9020 page 138
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Specifications SPECIFICATIONS Axle Oil Temperature
49°C 120°F
Engine Speed
Slow Idle
Cross Differential Lock Pressure—Axle Cooling Manifold Pressure
2758—3033 kPa 27—30 bar 400—440 psi
[1] LEGEND: 5 Front Axle Cooling Manifold
Front Axle Cooling Manifold Drive machine to warm axle oil to normal operating temperature. Item
Measurement
Specification
Axle Oil
Temperature
49°C 120°F
[2] - Prepare machine for service. Park and Prepare for Service Safely . (Group 9000-01.) [3] CAUTION: Avoid personal injury. Machine may roll when park brake is released. Use chocks in front of and behind wheels. Install wheel chocks in front of and behind wheels. [4] - Middle and Rear Axle Differential Pressure— Activate Service Mode. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [5] - Go to Diagnostics/Calibrations/Hydraulic. Select Set CDL Pressure. [6] - Go to Diagnostics/Readings/CCU/Input Sensors. Select Middle CDL Pressure or Rear CDL Pressure depending on the axle that is being tested. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) [7] - Run engine at specification. Item
Measurement
Specification
Engine
Speed
Slow Idle
[8] →NOTE: The front, middle, and rear axle need to be tested and adjusted independently of one another, for the differential manifold location of each axle, see Hydraulic System Component Location . (Group 9025-15.) Engage the cross-axle differential lock. See Using Differential Lock . (Operator’s Manual.) Record readings.
<- Go to Section TOC
Section 9020 page 139
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Item
Measurement
Specification
Cross Differential Lock Pressure—Axle Cooling Manifolds
Pressure
2758—3033 kPa 27—30 bar 400—440 psi
If pressure is not to specification, check for kinked or restricted lines or replace pumps.
<- Go to Section TOC
Section 9020 page 140
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
Group 25: Tests
Inter-Axle Differential Lock (IDL) Pressure Test Specifications SPECIFICATIONS Transmission Oil Temperature
80—90°C 175—195°F
Engine Speed—Slow Idle
900 rpm
Inter-Axle Differential Lock Pressure
1600—1800 kPa 16—18 bar 231—261 psi
Essential Tools ESSENTIAL TOOLS 202839 1/2 Quick Coupler x 7/16-20 ORB
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure/Temperature Analyzer JT02161 Transducer 3500 kPa (35 bar) (500 psi) JT02159 6.1 m (20 ft.) Cable with Couplers
Transmission Test Port Location LEGEND: 1 2 3 4 5 6 7 8 9 10 11 <- Go to Section TOC
Lube Pressure Test Port Torque Converter Lockup Test Port Clutch V Test Port Hydraulic System Pressure Test Port Clutch E Test Port Clutch G Test Port Clutch C Test Port Clutch F Test Port Clutch A Test Port Clutch R Test Port Clutch B Test Port Section 9020 page 141
TM12406-OPERATION AND TEST MANUAL
Section 9020 - POWER TRAIN
12
Group 25: Tests
Clutch D Test Port
[1] - With engine OFF. Install 202839 Quick Coupler to clutch G test port (6). 1/2 Quick Coupler x 7/16-20 ORB 202839 Installed in pressure port for testing equipment attachment. [2] - Attach JT02161 Transducer, JT02159 Cable with Couplers, and JT02158 Digital Pressure/Temperature Analyzer to quick coupler installed on clutch G test port. Transducer 3500 kPa (35 bar) (500 psi) JT02161 Connect to pressure port. 6.1 m (20 ft.) Cable with Couplers JT02159 Cable extension between transducer and digital pressure and temperature analyzer. Digital Pressure/Temperature Analyzer JT02158 To measure pressure. [3] - Start machine and warm up transmission to normal operating temperature. See Transmission Warmup Procedure . (Group 9020-25.) Item
Measurement
Specification
Transmission Oil Normal Operating
Temperature
80—90°C 175—195°F
[4] - Run engine at specification. Item
Measurement
Specification
Engine RPM
Engine Speed
900 rpm
[5] CAUTION: Avoid personal injury from unexpected machine movement. Perform procedure in an open area away from other people and machines. Engage the inter-axle differential lock (IDL). See Using Differential Lock . (Operator’s Manual.) [6] - Record the pressure reading and compare to specification. Item
Measurement
Specification
Inter-Axle Differential Lock Pressure
Pressure
1600—1800 kPa 16—18 bar 232—261 psi
If the inter-axle differential lock (IDL) does not engage, see Inter-Axle Differential Lock (IDL) Does Not Work . (Group 9020-15.)
Checking Controlled Traction Clutch (Differential Lock) Condition Specifications SPECIFICATIONS Controlled Traction Clutch Controlled Traction Clutch Slippage Minimum
125 N˙m 92 lb-ft
Controlled Traction Clutch Slippage Maximum
325 N˙m 240 lb-ft
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Section 9020 page 142
TM12406-OPERATION AND TEST MANUAL
HYDRAULIC SYSTEM
(g) by Belgreen v2.0
[1] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Raise one wheel off the ground and place a 20-ton floor stand under axle housing. Install chocks in front of and behind the wheel still on the ground. [2] - Disconnect drive shaft from input yoke. [3] - Using a torque wrench, turn the input yoke and record torque required. [4] - Compare recorded torque to specifications. Replace controlled traction clutch if torque is below specifications. Item
Measurement
Specification
Controlled Traction Clutch Slippage Minimum
Torque
125 N˙m 92 lb-ft
Controlled Traction Clutch Slippage Maximum
Torque
325 N˙m 240 lb-ft
Middle and Rear Axle Oil Sampling Procedure [1] - Start the machine and warm system to normal operating temperature. Operate machine functions so fluid is agitated throughout system. [2] - Once system has reached operating temperature, operate engine at slow idle and park machine. Item
Measurement
Specification
Engine
Speed
Slow Idle
[3] →NOTE: In order for axle oil to be present at sample valves, CAN monitor unit (CMU) must be in hydraulic calibration mode. Select hydraulic calibration mode on the CAN monitor unit (CMU). See CAN Monitor Unit (CMU)—Calibrations . (Group 9015-16.) [4] - Locate sample valves on unit. See Fluid Sampling Test Ports . (Operator’s Manual.) [5] IMPORTANT: Avoid contamination in sample. Clean dust cap on sample valve prior to removal. Clean and remove dust caps from the valves. [6] - Prime sample valves, obtain fluid sample, and send sample to lab. See Fluid Sampling Procedure . (Group 9010-25.) [7] - Install dust caps.
<- Go to Section TOC
Section 9025 page 143
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Section 9025 - HYDRAULIC SYSTEM Table of contents Group 05 - Theory of Operation ............................................................................................................. 1 Articulated Dump Truck Hydraulic System Operation .......................................................................... 1 Main Hydraulic Pump Operation ........................................................................................................... 3 Main Hydraulic Pump Load Sense Operation ........................................................................................ 5 Service Brake System Operation .......................................................................................................... 7 Steering and Secondary Steering System Operation ............................................................................ 8 Steering Valve Operation ................................................................................................................... 10 Secondary Steering Pump Operation .................................................................................................. 12 Hydraulic System Manifold Operation ................................................................................................ 14 Fan Drive System Operation ............................................................................................................... 20 Group 15 - Diagnostic Information ...................................................................................................... 23 Hydraulic System Schematic .............................................................................................................. 23 Hydraulic System Component Location .............................................................................................. 34 No Hydraulic Functions Diagnostic Procedure .................................................................................... 44 All Hydraulic Functions Slow Diagnostic Procedure ............................................................................ 45 Hydraulic Oil Overheats Diagnostic Procedure ................................................................................... 47 Main Hydraulic Pump Noisy Diagnostic Procedure ............................................................................. 48 Dump Body Will Not Rise Diagnostic Procedure ................................................................................. 50 Onboard Weighing (OBW) Does Not Function Properly Diagnostic Procedure .................................... 52 Hydraulic Fan Motor Not Working Diagnostic Procedure .................................................................... 56 Hydraulic Fan Runs Only at Full Speed Diagnostic Procedure ............................................................ 58 Poor or No Service Brakes .................................................................................................................. 58 Service Brake Pads Excessive Wear ................................................................................................... 58 Time Between Service Brake Accumulator Charging Cycles Too Short .............................................. 58 Service Brake Overheats .................................................................................................................... 58 Service Brake Cooling Oil Leaking ...................................................................................................... 59 Service Brake Noise and Vibration ..................................................................................................... 59 Service Brakes Do Not Fully Release .................................................................................................. 59 Slow or No Steering Function Diagnostic Procedure ........................................................................... 60 Constant Steering Needed to Maintain Straight Travel Diagnostic Procedure .................................... 61 Steering Erratic Diagnostic Procedure ................................................................................................ 62 Steering Soft or Spongy Diagnostic Procedure ................................................................................... 63 Steering Wheel Free Play Diagnostic Procedure ................................................................................. 63 Steering Locks Up Diagnostic Procedure ............................................................................................ 65 Steering Wheel Turns by Itself Diagnostic Procedure ......................................................................... 66 Machine Turns in Opposite Direction as Steering Wheel Diagnostic Procedure .................................. 66 Machine Turns With Steering Valve in Neutral Diagnostic Procedure ................................................. 66 Group 25 - Test ....................................................................................................................................... 68 JT02156A Digital Pressure/Temperature Analyzer Kit Installation ...................................................... 68 Hydraulic System Warmup Procedure ................................................................................................ 70 Cycle Time Test .................................................................................................................................. 71 Main Hydraulic Pump Margin and Maximum Pressure Test and Adjustment ...................................... 73 Dump Body Pilot Pressure Test and Adjustment ................................................................................. 76 Dump Body Manual Lowering & Bin Tip Circuit Pressure Relieving Procedure ................................... 79 Priority Valve Test .............................................................................................................................. 81 Service Brake Accumulator Pressure Reducing Valve Test and Adjustment ....................................... 81 Service Brake Accumulator Charge Valve Test and Adjustment ......................................................... 81 Service Brake Low Pressure Switch and Service Brake Accumulator Charge Test ............................. 81 Front and Rear Service Brake Accumulators Pressure Test and Charge Procedure ............................ 81 Service Brake Valve Test .................................................................................................................... 81 <- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Electronic Brake Valve (EBV) Test ...................................................................................................... 81 Axle Cooling Pump Pressure Test and Flow Test ................................................................................ 82 Orbital Steering Valve Leakage Test .................................................................................................. 83 Steering Relief Valve Pressure Test and Adjustment .......................................................................... 86 Steering Cylinder Leakage Test .......................................................................................................... 89 Dump Body Heat Diverter Valve Pressure Test .................................................................................. 90 Hydraulic Fan Circuit Flow Test .......................................................................................................... 92
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TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
Group 05 - Theory of Operation Articulated Dump Truck Hydraulic System Operation The articulated dump truck hydraulic system is a closed-center, load-sensing system and consists of the following circuits: Steering Secondary Steering Dump Body Park Brake Service Brake Differential Lock Axle Cooling Active Suspension Right and Left Cooling Fan Hydraulic Cooling Cab Tilt For reference, see Hydraulic System Schematic and see Hydraulic System Component Location . (Group 9025-15.) The system oil is stored in the hydraulic reservoir, and from there the oil is sent to the main hydraulic pump. Main Hydraulic Pump— The main hydraulic pump is a variable-displacement, axial-piston pump with a load-sensing and pressure-compensating regulator valve. The regulator valve controls pump flow rate by changing the swash plate angle to meet the load demand of functions actuated and to destroke the pump to residual (low standby) pressure when all functions are in neutral. See Main Hydraulic Pump Load Sense Operation . (Group 9025-05.) The pump is driven by the transmission auxiliary drive. The pump provides hydraulic oil flow to: Orbital Steering Service Brake Park Brake Active Suspension Right Side Fan Motor Drive Motor for Middle and Rear Axle Cooling Pumps Dump Body Control Circuits An attenuator is located in the main hydraulic pump-to-hydraulic system manifold line to help suppress pump noise. For more information, see Main Hydraulic Pump Operation . (Group 9025-05.) Hydraulic System Manifold— The hydraulic system manifold controls and distributes hydraulic oil through outlet ports to all the components in the hydraulic system that were mentioned above. The manifold is a replaceable cartridge-valve-type manifold. The steering and service brake circuits are given priority by the priority valve located in the manifold. See Hydraulic System Manifold Operation . (Group 9025-05.) Dump Body Control Valve— The dump body control valve is a closed-center valve with a load sense passage. The valve is incorporated into the hydraulic system manifold. The function of the dump body control valve is to route hydraulic oil to and from the dump body cylinders. The dump body cylinders are double-acting cylinders that raise and lower the dump body. The load sense passage is used to send a signal from the work ports through the hydraulic system manifold to the pump regulator valve when the valve is actuated. The load sense passage is open to return when the valve is in neutral. The valve also contains a dump body raise circuit relief valve and a dump body lower circuit relief valve. Steering Valve— The steering valve is a closed-center valve with a load sense passage. The valve is a wide-angle, variabledisplacement (flow amplification) valve with integrated anticavitation and relief valves. The effective displacement of the steering valve depends on the speed at which the valve is turned. The steering valve routes and controls hydraulic oil to and from the steering cylinders. The load sense passage is used to send a signal from the work port to the hydraulic system manifold and then to the pump regulator valve when the valve is actuated. The load sense passage is open to return when the valve is in neutral. The steering cylinders are double-acting cylinders that steer the truck by articulating the front and rear frames. See Steering and Secondary Steering System Operation . (Group 9025-05.) Secondary Steering— If there is a malfunction of the engine or main hydraulic pump, a ground-driven secondary steering system is used to provide supply oil flow for the steering circuit while the machine is moving in the forward direction only. Secondary steering will not function while the machine is moving rearward. The system consists of: Secondary Steering Pump One Check Valve (located in the pressure monitoring line) One Anti-Cavitation Valve (located on the pump) <- Go to Section TOC
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Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
Two Check Valves (located in the hydraulic system manifold) Secondary Steering Pump and Check Valves— The pump is a fixed-displacement gear pump with a load-sensing and pressure-compensating regulator valve. The residual pressure setting for the secondary steering pump is lower than the residual pressure setting for the main hydraulic pump. The pump is mounted on the rear of the transmission and is grounddriven as long as the gear train is being turned by the moving machine. Main pump pressure is felt at the end of the pilotoperated control spool of the secondary steering pump. This pressure will overcome the spring at the opposite end of the control spool, directing the oil flow to tank. If main pump pressure is lost, the spring will shift the spool, directing the oil to the steering circuit of the hydraulic system manifold. Two check valves in the hydraulic system manifold, are used to isolate the main hydraulic circuit and the secondary steering circuit. The secondary steering pump anti-cavitaion valve provides a path for oil to flow from the suction side of pump to the outlet side when the machine is moving in reverse. See Secondary Steering Pump Operation . (Group 9025-25.) Service Brake Accumulators— The front and middle axle service brake apply accumulators are piston-type, nitrogencharged accumulators. The function of the accumulators is to provide a signal to the service brake accumulator charge valve, regulating the load sense signal to the main hydraulic pump to maintain the pressure of the service brake accumulators between a lower and upper charge limit. The front and middle axle service brake apply accumulators are used to store service brake oil under pressure, which is then used to apply the service brakes when the service brake valve is actuated. Service Brake Valve— The service brake valve is a dual-circuit, modulated valve. The function of the valve is to control the charged service brake oil from the accumulators to actuate the service brake pistons. The valve contains two separate circuits, each supplied by its own pair of accumulators. The top valve section is for the middle axle service brakes, and the bottom valve section is for the front axle service brakes. The service brake valve supplies charged service brake oil to the middle service brake pistons first and then to the front service brake pistons. See Service Brake System Operation . (Group 9020-05.) Electronic Brake Valve— An electronic brake valve is connected in parallel to the service brake valve, so the actual braking force is a combination of the foot brake and the electronic brake valve. The electronic brake valve is controlled by the chassis control unit (CCU). For information CCU, see Chassis Control Unit (CCU) Circuits Theory of Operation . (Group 9015-15.) Active Suspension— The front axle active suspension consists of the active suspension manifold, left and right struts, and a left and right strut accumulators. The four proportional solenoid valves located in the active suspension manifold control the oil going to and from the left and right struts. The four proportional solenoid valves are controlled by the CCU. Fan Motors— There are two electrically controlled, hydraulic fan motors, the left side fan motor and the right side fan motor. The left side fan sends air through: Engine Radiator 1 Air Conditioner Condenser Axle Oil Coolers Charge Air Cooler The right side fan sends air through: Engine Radiator 2 Transmission Oil Cooler Hydraulic Oil Cooler The left side fan motor receives its oil from the left side fan pump, and the right side fan motor receives its oil from the main hydraulic pump by way of the hydraulic system manifold. Fan speed is controlled by the CCU. Axle Cooling and Differential Lock Circuit— Each of the three axles is cooled by its own axle cooling pump. The front axle cooling pump is attached to the end of the left side fan pump. It draws oil from the front axle and sends it back to the front axle cooling manifold, where it is filtered and then sent through the front axle oil cooler before it is sent back through the axle for cooling. The differential lock is also engaged by oil from the front axle cooling manifold. Each axle cooling system is one continuous closed loop, independent of the main hydraulic system. The middle and rear axle cooling circuits are the same as the front axle cooling circuit, except that the rear axle oil does not flow through a cooler. The rear axle does not have inboard brakes, so much less heat is generated. The circulating pumps for the middle and rear axles are mounted to the rear frame and are driven by a hydraulic motor that is driven by pressure oil from the hydraulic system manifold. Return Filter— A return filter is used to filter return oil before it enters the hydraulic reservoir.
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Section 9025 page 2
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
Main Hydraulic Pump Operation
Main Hydraulic Pump Operation LEGEND: 1 2 3 4 5 6 7 8 9 10 600 604 614
Small Control Piston Outlet Port Compensator Valve Residual Valve Pump Regulator Valve Load Sense Port Large Control Piston Tank Port Inlet Port Swash Plate High Pressure Oil Return or Pressure Free Oil Load Sense Oil
The main hydraulic pump is a variable-displacement, axial-piston pump with a load-sensing and pressure-compensating pump <- Go to Section TOC
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Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
regulator valve (5). Pump displacement is varied by the angle of swash plate (10). Swash plate angle is controlled by the small control piston (1) and large control piston (7). The small control piston has high pressure oil (600) and spring pressure applied to it at all times, trying to keep the pump at maximum displacement. High pressure oil is applied to or released from the large control piston by the residual valve (4), varying pump displacement per load sense signal from load sense port (6). At full system pressure, the compensator valve (3) shifts to route high pressure oil to the large control piston, destroking the pump. As the angle of swash plate is increased, the pump pistons move in and out of their bores and displace oil as the cylinder block is turned by the pump drive shaft. The pistons move into their bores during the first half of each revolution, and out of their bores during the last half of the revolution. The piston bores are filled with oil through the inlet port (9) and valve plate as the pistons move out of their bores. The pistons moving into their bores push oil out through the valve plate to the small control piston, pump regulator valve, and through the outlet port (2) to the hydraulic system manifold. Unused control oil and case drain oil exit the pump at the tank port (8) and return to the reservoir. Pressure compensation is a constant-pressure system that requires a closed-center hydraulic system. As soon as the engine is started, supply oil flows from the pump to the closed-center valves. The pressure in the hydraulic system increases and causes the residual valve to destroke the pump at residual pressure. The residual pressure ensures that immediate system pressure is available on demand when a function is actuated. Load sense system pressure is used to regulate the residual valve to stroke or destroke the pump as needed. No matter what the load demand is, even when using more than one function, as long as the total demand does not exceed the pump′s capability, the pump will deliver the exact amount of oil required to move the load. The pump is driven by the transmission auxiliary drive.
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Section 9025 page 4
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Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
Main Hydraulic Pump Load Sense Operation
Main Hydraulic Pump Regulator—Residual Pressure LEGEND: 1 Pump Regulator 2 Residual Spool 3 Residual Spring 4 Compensator Spring 5 Compensator Spool 6 Case Drain 7 To Control Piston 8 From Pump Outlet 600 Supply Oil 604 Return Oil 614 Load Sense Oil Residual Pressure— As soon as the pump is driven, supply oil (600) flows to the pump regulator (1), which consists of a residual valve and a compensating valve. As the supply oil pressure rises, the residual spool (2) having the smaller spring will start to shift. The spool will shift toward the residual spring (3) until it allows supply oil to be directed into the control piston (7), destroking the pump and reducing flow until the pressure at the pump outlet (8) is equal to the residual pressure setting. The pump will maintain this residual pressure until the hydraulic system′s needs are greater (function actuated). When hydraulic functions are not actuated, the pump produces only enough flow to maintain the residual pressure. The load sense oil (614) at this time is at a minimal pressure because the load sense circuits are open to return.
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Section 9025 page 5
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
Main Hydraulic Pump Regulator—Working Pressure LEGEND: 1 Pump Regulator 2 Residual Spool 3 Residual Spring 4 Compensator Spring 5 Compensator Spool 6 Case Drain 7 To Control Piston 8 From Pump Outlet 600 Supply Oil 604 Return Oil 614 Load Sense Oil Working Pressure— When a function is actuated, load sense oil pressure (614) to the pump regulator (1) rises. This rising load sense pressure and the force of the residual spring (3) work together to overcome the pressure of the supply oil (600) on the opposite side of the residual spool (2). The spool will then slide over (away from spring), opening the control piston (7) to case drain (6), stroking the pump and increasing flow as needed.
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Section 9025 page 6
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Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
Main Hydraulic Pump Regulator—Compensating Pressure LEGEND: 1 Pump Regulator 2 Residual Spool 3 Residual Spring 4 Compensator Spring 5 Compensator Spool 6 Case Drain 7 To Control Piston 8 From Pump Outlet 600 Supply Oil 604 Return Oil 614 Load Sense Oil Compensating Pressure— As the hydraulic system needs are met and the supply oil (600) pressure continues to rise, the increasing supply oil pressure starts to overcome the compensator spring (4), sliding the compensator spool (5) toward the spring. The spool will then direct the high pressure supply oil into the control piston (7) destroking the pump but providing enough flow to maintain compensating pressure in the system. Compensating pressure is set lower than the system relief valve pressure. The system relief valve is used to protect the system against sudden pressure spikes. High system pressure oil is also conveyed into the load sense circuit. The high pressure load sense oil (614) plus the force of the residual spring (3) will keep residual spool (2) shifted away from the spring.
Service Brake System Operation See Service Brake System Operation . (Group 9020-05.)
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Section 9025 page 7
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Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
Steering and Secondary Steering System Operation
Steering and Secondary Steering System LEGEND: 1 2 3 4 <- Go to Section TOC
Steering Valve Steering Cylinder (2 used) Main Pressure Relief Brake Pressure Regulator Section 9025 page 8
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Section 9025 - HYDRAULIC SYSTEM
5 6 7 8 9 10 11 12 13 14 15 600 602 604 606 614 B12 B13 Y6
Group 05: Theory of Operation
Steering/Brake Priority Valve Secondary Steering Pump Check Valve Main Hydraulic Pump Check Valve Steering Compensating Valve Steering Load Sense Relief Valve To Hydraulic Reservoir To Hydraulic Return Manifold Main Hydraulic Pump Secondary Steering Pump Check Valve Bridge Hydraulic System Manifold Supply Oil Secondary Supply Oil Return Oil Trapped Oil Load Sense Oil Main Hydraulic Pressure Sensor Secondary Steering Pressure Sensor Not Used
The function of the steering system is to route supply oil (600) from the main hydraulic pump (12) to the steering valve (1). The steering valve then controls the oil flow used to extend and retract the steering cylinders (2). When the steering wheel is turned, the load sense signal from the steering valve enters the hydraulic system manifold (15) at port LSO. The load sense signal is then sensed at the secondary steering pump (13) via port LSEP. At the same time, the load sense signal shifts the shuttle valves, pressurizes the spring chamber of the steering/brake priority valve (5), and sends a signal to the main hydraulic pump via port LSP. The load sense signal will not exceed the steering load sense relief valve (9) pressure setting. The main hydraulic pump supplies the required flow rate through port P, main hydraulic pump check valve (7), steering compensating valve (8), and out of port O to steering valve port P. When the steering wheel is not being turned, the load sense signal is open to the hydraulic reservoir through the steering valve and the main hydraulic pump will return to residual pressure. The oil in the steering cylinders is trapped, and the machine is held at that relative position. →NOTE: Machine must be moving in the forward direction for secondary steering pump to work. The ground-driven secondary steering pump will assist with oil flow to steer the machine if the main hydraulic pump cannot deliver the flow required. Low oil flow may occur during an attempt to rapidly steer the machine at slow engine speed. Under normal steering operation, the pressure of the secondary steering pump at port P2 is below that of the main hydraulic pump at port P, creating a differential pressure across secondary steering pump check valve (6). When the main hydraulic pump cannot meet the flow requirements to steer the machine, the pressure in the main hydraulic pump circuit decreases the load sense signal at port LSP. The load sense signal to the secondary steering pump via port LSEP is the same as that of the main hydraulic pump at port LSP, enabling the pressure of the secondary steering pump at port P2 to increase and overcome the pressure differential across the secondary steering pump check valve. Flow from the secondary steering pump, via port P2, eventually supplements the flow from the main hydraulic pump to the steering valve via port O. The rpm of the secondary steering pump is dependent on the machine travel speed. Supply oil flow available to steer the machine is reduced proportionately as the travel speed decreases. When the machine stops, there is no secondary steering pump flow. The secondary steering system is also used to provide oil flow to the steering circuit if there is a malfunction of the engine, transmission, or main hydraulic pump. The machine must be moving forward only for the secondary steering system to function. The secondary steering system will not function while the machine is moving rearward. The system consists of the secondary steering pump, main hydraulic pump check valve, secondary steering pump check valve, and secondary steering pump anti-cavitation valve (14). The secondary steering pump is a fixed-displacement gear pump, with a load-sensing spool valve. The valve pressure setting for the secondary steering pump is lower than the residual valve pressure setting for the main hydraulic pump. The secondary steering pump is mounted on the transmission case and is ground-driven as long as the gear train is being turned by the forward movement of the machine. The secondary steering pump check valve is used to block oil flow from the main hydraulic pump to the secondary steering pump circuit. In the event of a malfunction, main hydraulic pump check valve blocks oil flow from the secondary steering pump to the main hydraulic pump, dump body control valve, and service brake accumulator charging circuit. for more information on the secondary steering pump, see Secondary Steering Pump Operation . (Group 9025-05.)
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Section 9025 page 9
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
Steering Valve Operation
Steering Valve Operation LEGEND: 1 2 3 4 <- Go to Section TOC
In Neutral Steering Cylinder (2 used) Gerotor Load Sense Port LS to Hydraulic System Manifold Port LSO Section 9025 page 10
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
5 Sleeve 6 Spool 7 Steering Shaft 8 Port T 9 Port PP to Hydraulic System Manifold Port PP 10 Port P From Hydraulic System Manifold Port O 11 Circuit Relief Valve (2 used) 12 Anticavitation Valve (2 used) 600 High Pressure Oil 601 Working Pressure Oil 604 Return Oil 606 Trapped Oil 614 Load Sense Oil The steering valve is a variable-displacement (flow amplification), closed-center valve. Main valve components are the spool (6), sleeve (5), and the gerotor (3). Also included are the anticavitation valves (12), and circuit relief valves (11). When the steering wheel is not being turned, the valve is in neutral (1). In neutral, the spool and sleeve are held in alignment by the centering spring blocking the flow of high pressure oil (600) through the sleeve to the spool and gerotor. Oil at the left and right work ports to the steering cylinders is trapped (606) by the sleeve holding the machine frames stationary. Turning the steering wheel and shaft (7) left or right, turns the spool relative to the sleeve, opening passages so supply oil from the hydraulic system manifold port O flows through the sleeve into the spool. From the spool, working pressure oil (601) flows to the gerotor, causing the gerotor gear and sleeve to turn. Working pressure oil flow is metered by the gerotor back into the spool. There it is routed through the sleeve and out the left or right work port to the respective ends of the steering cylinders, turning the machine. Working pressure oil also flows out the load sense port (4), sending a load sense signal back through the hydraulic system manifold port LSO to the main hydraulic pump regulator valve to regulate pump flow. A load sense signal also goes to the spring chamber of the priority valve and to the steering load sense relief valve. Return oil (604) flows back from the steering cylinders, through the right or left work port, sleeve, spool, and through the return port T (8) to the hydraulic system manifold. As steering operation is stopped, the centering spring and gerotor continue to turn the sleeve until the sleeve and spool are in alignment, stopping the flow of oil through the spool to the gerotor. At this point, the valve is in neutral and remains there until the steering wheel and shaft are turned again. The valve′s variable displacement (flow amplification) is proportional to the speed at which the steering wheel is turned. When the steering wheel is turned slowly, the valve meters oil only through the gerotor to the steering cylinders and, thus, the effective displacement is equal to the gerotor displacement. When the steering wheel is turned rapidly, the spool moves more, relative to the sleeve opening passages. As a result, additional oil is allowed to bypass the gerotor. This increases the effective valve displacement, and flow amplification occurs. Relief valves are used to relieve high-pressure oil from a pressure spike created in the steering cylinders while steering is in neutral. In neutral, the steering valve blocks the flow of oil to and from the cylinders. A pressure spike, created by the impact of the front or rear wheels against an obstacle, is transmitted to the steering cylinders, causing slight cylinder movement. The cylinder movement that caused the pressure spike also causes a pressure drop and a void in the opposite end of the cylinders. Because of the pressure differential across the anticavitation valve, the pressure in the return passage pushes the valve open and oil flows into the void, preventing cavitation. Oil not used flows out of port T and then back to the hydraulic return manifold.
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Section 9025 page 11
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Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
Secondary Steering Pump Operation
Secondary Steering Pump—Engine Shut Down, Machine Moving Forward LEGEND: 1 2 3 4 <- Go to Section TOC
Port LSEP Port P2 Tank Port Spool Valve Section 9025 page 12
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Section 9025 - HYDRAULIC SYSTEM
5 6 7 8 9 10 11 600 604 614
Group 05: Theory of Operation
Port PM Check Valve Check Valve Inlet Passage Gear Pump Load Sense Relief Valve Spring High Pressure Oil Return Oil Load Sense Oil
The secondary steering pump is a fixed-displacement gear pump (9) with load-sensing spool valve (4) and load sense relief valve (10). It draws its oil directly from the hydraulic reservoir. The secondary steering pump is mounted on the rear of the transmission and is ground driven. This will provide steering capabilities as long as the gear train is being turned by the machine moving in the forward direction only. When the machine is not moving, there is no secondary steering pump flow. In normal machine operation, when the engine is running and there is flow from the main hydraulic pump, main pump pressure flows into port PM (5), where it flows past check valve (6) to the end of the load-sensing spool, causing the spool to move to the left, compressing the spring (11) at the other end of the spool. With the spool in this position, the oil flow created by the secondary steering pump is directed through the tank port (3) at the end of the pump cover to the reservoir. If the engine were to shut down and main hydraulic pump flow was lost, the spring at the end of the load sensing spool would move the spool to the right, allowing secondary steering pump oil to flow out of port P2 (2) to port P2 of the hydraulic system manifold to supply the steering circuit with pressure oil so the machine can be steered safely to a stop. The secondary steering pump anti-cavitation valve (7) provides a path for oil to flow from the suction side of the pump to the outlet side while traveling in reverse. Load sense oil from the hydraulic system manifold enters the secondary steering pump through port LSEP (1). The relief valve monitors load sense pressure oil on the spring side of the spool valve and relieves oil into the inlet passage (8) of the pump.
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Section 9025 page 13
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
Hydraulic System Manifold Operation
Hydraulic System Manifold—Front View
Hydraulic System Manifold—Rear View
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Section 9025 page 14
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
Hydraulic System Manifold—Right Side View
Hydraulic System Manifold—Left Side View
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Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
Hydraulic System Manifold—Top View
Hydraulic System Manifold—Schematic LEGEND: 1 2 3 4 5
Electronic Brake Supply Port EB Upper Brake Valve Supply Port ACC1 Lower Brake Valve Supply Port ACC2 Service Brake Accumulator Charge Valve X3 Over Center Orifice 0.8
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Section 9025 - HYDRAULIC SYSTEM
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 600 604 606
Group 05: Theory of Operation
Dump Body Heat Diverter Port BH (if equipped) Priority Valve Load Sense Shuttle Valve Dump Body Pilot Pressure Test Port PS Front Axle Brake Accumulator Port ACC2 Middle Axle Brake Accumulator Port ACC1 Dump Body Spool Valve Fan Load Sense Shuttle Valve Load Sense to Main Pump Pressure Test Port LSPM Secondary Steering Test Cartridge (S.N. —XXXXXX) Test Port LSFD Right Side Fan Speed Solenoid Valve Secondary Steering Pump Check Valve Steering Load Sense Port LSO With Orifice 0.91 Secondary Steering Pump Load Sense Port LSEP Orbital Steering Valve Supply Port O Main Hydraulic Pump Check Valve Port PP With Orifice 0.8 Axle Cooling Hydraulic Motor Supply Port BC Supply From Secondary Steering Pump Port P2 Fan Compensating Valve Secondary Steering Pressure Sensor B13 Main Hydraulic Pressure Test Port PM Main Hydraulic Pressure Sensor B12 Brake Accumulator Pressure Test Port MP4 Brake Accumulator Low Pressure Switch B35 Service Brake Accumulator Charge Orifice 0.7 Middle Axle Brake Pressure Test Port ACC1 Dump Body Pilot Pressure Regulator Valve Park Brake Manifold Supply Port S4 Tank Port to Return Manifold Port T Steering Load Sense Relief Valve Orifice 0.8 Steering Pressure Test Port OM Steering Compensating Valve Dump Body Pressure Reduction Valve Dump Body Cylinder Head End Supply Port A Priority Valve Axle Cooling Cut-Off Solenoid Valve Axle Fixed Flow Control Valve Dump Body Down Circuit Relief and Anticavitation Valve Dump Body Cylinder Rod End Supply Port B Dump Body Up Circuit Relief and Anticavitation Valve Over Center Check Valve Dump Body Load Sense Shuttle Valve Axle Cooling Load Sense Shuttle Valve Fan Cut-Off Solenoid Valve Load Sense Pressure Test Port LSM Active Suspension Manifold Supply Port AS Dump Body Load Holding Pilot Valve Orifice 1.0 Dump Body Load Holding Solenoid Valve Flow Control Valve X5 Dump Body Up Solenoid Valve Dump Body Down Solenoid Valve Front Axle Brake Pressure Test Port ACC2 Brake Charge Balancing Spool Brake Circuit Check Valve With Orifice Tank Port to Reservoir Port T Service Brake Accumulator Pressure Regulator Valve X2 Main Pressure Relief Valve Right Side Fan Motor Supply Port FD Load Sense to Main Pump Control Valve Port LSP Inlet From Main Hydraulic Pump Port P Port PM to Secondary Steering Valve Port PM High Pressure Oil Return Oil Trapped Oil
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Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
609 Pilot Oil 614 Load Sense Oil B12 Main Hydraulic Pressure Sensor B13 Secondary Steering Pressure Sensor B35 Brake Accumulator Low Pressure Switch Y2 Axle Cooling Cut-Off Solenoid Y6 Secondary Steering Test Solenoid (S.N. —XXXXXX) Y11 Right Side Fan Cut-Off Solenoid Y23 Dump Body Down Control Solenoid Y24 Dump Body Up Control Solenoid Y25 Load Holding Pilot Solenoid Y26 Dump Body Reduction Solenoid Y71 Right Side Fan Speed Solenoid For a complete hydraulic system schematic and the hydraulic system component location, see Hydraulic System Schematic and see Hydraulic System Component Location . (Group 9025-15.) The hydraulic system manifold controls and distributes hydraulic oil through outlet ports to all components in the hydraulic system. The hydraulic system manifold is a replaceable cartridge-valve-type manifold. Numbers and letters are stamped on the manifold to help locate and identify components and ports. The illustrated views given are with the hydraulic system manifold installed in the machine. Test ports ACC1 (32) and ACC2 (60) are equipped with high pressure quick couplers for making test connections to hydraulic system. Test ports LSM (52), PM (27), S4 (34), LSFD (15), PS (8), and OM (38) are connected by hydraulic lines to the test port manifold located in the left rear of the engine compartment. The brake accumulator low pressure switch B35 (30), closes to ground when service brake accumulator pressure decreases below the lower limit of accumulator charge band. The monitor will then display a warning. The priority valve (42) gives priority to the steering valve and service brake accumulator charging circuit over the dump body control valve if supply oil flow from main hydraulic pump is not enough to satisfy the load demand. During dump body raise operation, the priority valve remains open if the pressure to operate the service brake accumulator charging and steering circuits is less than that of the dump body raise circuit. Oil takes the path of least resistance, meeting the load demand of service brake accumulator charging and steering circuits. When pressure to operate the service brake accumulator charging or steering circuits is higher, their higher load sense signal assists the priority valve spring to move the valve spool, reducing the flow of oil to the dump body control valve. The main hydraulic pump can now meet the charging or steering circuit load demand. The priority valve load sense shuttle valve (7) routes the higher load sense signal from the steering valve or service brake accumulator charging circuit to the spring chamber of the priority valve and through the fan load sense shuttle valve (12), dump body load sense shuttle valve (49), and out the LSP port (67), to the main hydraulic pump regulator valve. The steering load sense relief valve (36) relieves excess load sense signal from the steering valve. The secondary steering pressure sensor B13 (26) monitors secondary steering pump pressure at port P2 (24). If main hydraulic pump pressure is lost, the secondary steering pump control valve will send steering pressure oil to port P2, and sensor B13 will send out a signal causing the secondary steering indicator to flash and the audible alarm to beep. The service brake accumulator charge valve X3 (4) maintains the service brake accumulators pressure between the upper and lower limit of the charge band. The service brake accumulator pressure regulator valve X2 (64) limits pressure to the service brake accumulators. The dump body down solenoid valve (59) (when energized) opens, pushing the dump body valve spool to the bottom position, allowing the dump body cylinder rod end to fill with pressure oil and the head end open to the hydraulic reservoir. When the dump body up solenoid valve (58) is energized, the dump body valve spool is moved to the top position, allowing the dump body cylinder head end to fill with pressure oil and the rod end open to the hydraulic reservoir. The spool is self-centering into the neutral position whenever the valve is not actuated. The dump body down circuit relief and anticavitation valve (45) relieves pressure in the dump body cylinder rod end circuit. The relief valve pressure setting is lower than the pressure setting for dump body up circuit relief valve. The anticavitation valve prevents cavitation from occurring when lowering the dump body with the engine not running. The dump body cylinder rod end supply port B (46) is connected to the dump body cylinder rod end. Return oil flows from port T (35) to the hydraulic return manifold. In neutral, the load sense circuit for the dump body control valve is connected to return port T so there is no load sense signal. The dump body cylinder head end supply port A (41) is connected to the dump body cylinder head end. The dump body up circuit relief and anticavitation valve (47) relieves pressure in the dump body cylinder head end circuit. The anticavitation valve prevents cavitation in the circuit if the cylinder is extended while the control valve is in neutral. The <- Go to Section TOC
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Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
dump body up circuit is also equipped with a load holding pilot valve (54) that holds the position of the dump body when the dump body valve spool is in neutral and a load holding solenoid valve (56) that allows the dump body to slowly float down through an orifice when the dump body valve spool is in neutral. Supply oil flows from the main hydraulic pump to the inlet port P (68). Secondary supply oil flows from the secondary steering pump to the secondary steering pump port P2 (24). The secondary steering pump check valve (17) blocks supply oil flow from the main hydraulic pump to the secondary steering pump. The check valve will open when the main hydraulic pump flow is low enough so that pressure drops below the pressure of the secondary steering pump, allowing the secondary steering pump to supply oil to the steering valve as long as the machine is moving. The load sense signal from the main hydraulic pump load sense port LSP (67), to the main hydraulic pump port X, causes the pump to go into stroke. The load sense signal from the secondary steering load sense port LSEP (19), to the secondary steering hydraulic pump port LSEP, causes the secondary steering pump control spool to shift, allowing oil to flow into the secondary steering pump port P2 (24). The main pressure relief valve (65) relieves supply oil pressure spikes to the return circuit. The brake circuit check valve with orifice (62), controls the rate of supply oil flow to the accumulators while the check valve holds a charge pressure in the service brake accumulators. The axle cooling cut-off solenoid valve (43) and the fan cut-off solenoid valve (51) are energized during engine start-up to momentarily reduce, or cut, the hydraulic load on the engine. Upper brake valve supply port ACC1 (2) supplies oil to the middle axle service brake valve, and the lower brake valve supply port ACC2 (3) supplies oil to the front axle service brake valve. Middle axle brake accumulator port ACC1 (10) supplies oil to the middle service brake apply accumulators and the front axle brake accumulator port ACC2 (9) supplies oil to the front service brake apply accumulators. The brake charge balancing spool (61) will react to any unbalance in pressure between the two service brake accumulators. This will enable the circuits to work independently in the event of a malfunction in either of the circuits. The service brake accumulator charge orifice (31) controls the rate of oil flow through the service brake accumulator charge valve X3 (4) to the return circuit when the service brake accumulators are charged. The dump body load sense shuttle valve (49) routes the higher load sense signal from the dump body spool valve (11) or the priority valve load sense shuttle valve (7) to the main hydraulic pump regulator port X. The steering load sense port LSO with orifice (18) receives the load sense signal from the steering valve port LS. The orbital steering valve supply port O (20) sends supply oil to the steering valve port P. The main hydraulic pump check valve (21) prevents secondary supply oil flow from the secondary steering pump from entering the service brake charging circuit, axle cooling motor, right side fan motor, front active suspension, and dump body control circuit. Manifold port AS (53) supplies oil to the front active suspension manifold. The flow control valve X5 (57) is used to manually lower the dump body. See Dump Body Manual Lowering & Bin Tip Circuit Pressure Relieving Procedure . (Group 9025-25.)
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Group 05: Theory of Operation
Fan Drive System Operation There are two electrically controlled, hydraulic fan motors, the left side fan motor and the right side fan motor.
Left Side Fan Circuit LEGEND: 1 From Hydraulic Reservoir 2 Left Side Fan Pump 3 Left Side Fan Speed Solenoid Valve 4 Left Side Fan Motor (non-reversing) 5 Left Side Fan Low Pressure Solenoid Valve 6 Left Side Fan Relief Valve 7 Hydraulic Fan Motor 8 Left Side Fan Motor (optional reversing) 9 Left Side Fan Reversing Spool 10 Left Side Reversing Fan Solenoid Valve 600 High Pressure Oil 604 Return or Pressure Free Oil Y9 Left Side Fan Speed Solenoid Y48 Left Side Fan Low Pressure Solenoid Y50 Left Side Reversing Fan Solenoid Left Side Fan— The left side fan sends air through: Engine Radiator 1 Air Conditioner Condenser Axle Oil Coolers Charge Air Cooler The left side fan motor (4) receives its oil from the left side fan pump (2). A left side fan speed solenoid valve (3) is located at the pump. This regulates the flow to the hydraulic fan motor (7). With left side fan speed solenoid (Y9) not energized, fan will turn at maximum speed; when solenoid is energized, fan will turn at minimum speed. The fan is equipped with a left side fan relief valve (6) to handle pressure spikes that could occur during start-up. During a fan shutdown, left side fan low pressure solenoid (Y48) is energized to slowly dump pressure oil to tank so fan can coast to a stop. An anticavatation valve allows oil to pass from the return side to the pressure side if necessary while fan is coming to a stop. Optional Reversing Fan— An optional reversing left side fan motor (8) is available and functions the same as the nonreversing fan motor except for the addition of the left side fan reversing spool (9) and the left side reversing fan solenoid valve (10). During a fan reversal, the speed solenoid valve at the pump is energized, causing the fan to drop to minimum speed, and the <- Go to Section TOC
Section 9025 page 20
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Section 9025 - HYDRAULIC SYSTEM
Group 05: Theory of Operation
fan low pressure solenoid is energized, bringing the fan speed down even lower. When the fan speed is low enough, the CCU energizes the left side reversing fan solenoid (Y50), which sends pressure oil to the end of the reversing spool, shifting the spool and reversing the direction of the fan. Reversing can be done manually through the CCU. For more information on the electrical components in the fan circuit, see Hydraulic Fan Control Circuits Theory of Operation . (Group 9015-15.)
Right Side Fan Circuit LEGEND: 12 Axle Cooling Cut-Off Solenoid Valve 13 Hydraulic System Manifold 14 Fan Compensator Valve 15 Right Side Fan Cut-Off Solenoid Valve 16 Pump Supply 17 Right Side Fan Speed Solenoid Valve 18 Right Side Fan Motor (non-reversing) 19 Right Side Low Pressure Solenoid Valve 20 Right Side Fan Relief Valve 21 Hydraulic Fan Motor 22 Right Side Fan Motor (optional reversing) 23 Right Side Fan Reversing Spool 24 Right Side Reversing Fan Solenoid Valve 600 High Pressure Oil 604 Return or Pressure Free Oil 614 Load Sense Oil Y2 Axle Cooling Cut-Off Solenoid Y11 Right Side Fan Cut-Off Solenoid Y49 Right Side Fan Low Pressure Solenoid Y51 Right Side Reversing Fan Solenoid Y71 Right Side Fan Speed Solenoid Right Side Fan— The right side fan sends air through: Engine Radiator 2 Transmission Oil Cooler Hydraulic Oil Cooler The right side fan motor (18) receives its oil from the main hydraulic pump by way of the hydraulic system manifold (13). Pump oil to the hydraulic fan motor is cut off during engine start-up. Once engine is running, right side fan cut-off solenoid (Y11) is de-energized, allowing pump oil to flow through the fan compensator valve (14) to the hydraulic fan motor (21). The compensator valve generates load sense oil, which flows into the load sense oil passage in the hydraulic system manifold, and is then sent to the main hydraulic pump control valve. <- Go to Section TOC
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Group 15: Diagnostic Information
A right side fan speed solenoid valve (17) is in the circuit that regulates fan speed by dumping load sense oil to the return circuit before it reaches the pump. Right side fan speed solenoid (Y71) is controlled by the CCU. The right side fan motor (18) is exactly the same as the fan motor used on the left side. The fan is equipped with a right side fan relief valve (20) to handle pressure spikes that could occur during start-up. During a fan shutdown, right side fan low pressure solenoid (Y49) is energized to slowly dump pressure oil to tank so fan can coast to a stop. An anticavatation valve allows oil to pass from the return side to the pressure side if necessary while fan is coming to a stop. Optional Reversing Fan— An optional reversing right side fan motor (22) is available and functions the same as the nonreversing fan motor except for the addition of the right side fan reversing spool (23) and the right side reversing fan solenoid valve (24). During a fan reversal, the speed solenoid valve at the hydraulic system manifold is energized, causing the fan to drop to minimum speed, and the fan low pressure solenoid is energized, bringing the fan speed down even lower. When the fan speed is low enough, the CCU energizes the right side reversing fan solenoid (Y51), which sends pressure oil to the end of the reversing spool, shifting the spool and reversing the direction of the fan. Reversing can be done manually through the CCU. For more information on the electrical components in the fan circuit, see Hydraulic Fan Control Circuits Theory of Operation . (Group 9015-15.)
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Group 15 - Diagnostic Information Hydraulic System Schematic
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Section 9025 page 23
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Hydraulic System Schematic (1 of 3)
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Section 9025 page 24
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LEGEND: 1 2 3 4 5 6 7 8 9 10 11 600 604 606 609 614 704 705 707 709 711 712 713 714 715 716 717 718 719 720 721 722 723 725 Y49 Y51
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Group 15: Diagnostic Information
Secondary Steering Pump Main Hydraulic Pump Attenuator Right Side Fan Motor (non-reversing) Right Side Fan Motor (optional reversing) Hydraulic Reservoir Hydraulic Return Manifold Cab Tilt Manifold Cab Tilt Cylinder Hydraulic Return Filter Hydraulic Oil Cooler High-Pressure Oil Return Oil Trapped Oil Pilot Oil Load Sense Oil To Front Axle Coolant Pump From Left Side Fan Pump From Park Brake Manifold From Active Suspension Manifold From Hydraulic Return Manifold From Axle Cooling Hydraulic Motor From Left Side Fan Motor From Left Side Fan Motor From Hydraulic System Manifold Port PM To Hydraulic System Manifold Port P2 From Orbital Steering Valve Port T To Hydraulic System Manifold Port LSEP To Hydraulic System Manifold Port P From LSP Shuttle Valve From Hydraulic System Manifold Port T From Hydraulic System Manifold Port T From Electric Brake Valve From Hydraulic System Manifold Port FD Right Side Fan Load Sense Relief Solenoid Right Side Reversing Fan Solenoid
Section 9025 page 25
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Hydraulic System Schematic (2 of 3)
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LEGEND: 12 13 14 15 16 17 18 19 22 600 604 606 609 614 701 702 703 706 708 710 715 716 717 718 719 720 721 722 723 725 B12 B13 B35 Y2 Y6 Y8 Y11 Y23 Y24 Y25 Y26 Y71
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Group 15: Diagnostic Information
Orbital Steering Valve Steering Cylinder Front Axle Brake Accumulator (2 used) Middle Axle Brake Accumulator (2 used) Dump Body Spool Valve Hydraulic System Manifold Electronic Brake Valve Brake Valve Dump Body Cylinder (2 used) High-Pressure Oil Return Oil Trapped Oil Pilot Oil Load Sense Oil To Middle Axle Service Brake Pistons To Front Axle Service Brake Pistons To Axle Cooling Hydraulic Motor To Park Brake Manifold To Active Suspension Manifold From Active Suspension Manifold Port LS To Secondary Steering Pump From Secondary Steering Pump To Hydraulic Return Manifold From Secondary Steering Pump Port LSEP From Main Hydraulic Pump To Main Hydraulic Pump To Hydraulic Return Manifold To Hydraulic Reservoir To Hydraulic Reservoir To Right Side Fan Motor Main Hydraulic Pressure Sensor Secondary Steering Pressure Sensor Brake Accumulator Low-Pressure Switch Axle Cooling Cut-Off Solenoid Secondary Steering Test Solenoid Electronic Brake Valve Solenoid Right Side Fan Cut-Off Solenoid Dump Body Down Control Solenoid Dump Body Up Control Solenoid Load Holding Pilot Solenoid Dump Body Reduction Solenoid Right Side Fan Speed Solenoid
Section 9025 page 27
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Hydraulic System Schematic (3 of 3) (S.N. —668586)
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LEGEND: 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 600 604 606 609 614 701 702 703 704 705 706 707 708 709 710 711 712 713 714 B15 B55 B58 B59 B60 B61 B62 B63 B64 B65 B67 B68 B69 Y9 Y38 Y39 Y40 Y41 Y45 Y46 Y48 Y50 <- Go to Section TOC
Group 15: Diagnostic Information
Park Brake Manifold Park Brake Release Piston Front Axle Cooling Pump Left Side Fan Pump Left Strut Accumulator Left Strut Active Suspension Manifold Right Strut Right Strut Accumulator Front Axle Cooling Manifold Front Axle Oil Cooler Differential Lock (3 used) Service Brake Piston (4 used) Front Axle Axle Cooling Hydraulic Motor Middle Axle Cooling Pump Rear Axle Cooling Pump Middle Axle Cooling Manifold Middle Axle Oil Cooler Middle Axle Rear Axle Cooling Manifold Rear Axle Left Side Fan Motor (non-reversing) Left Side Fan Motor (optional reversing) Front Axle Pressure Reducing Valve High-Pressure Oil Return Oil Trapped Oil Pilot Oil Load Sense Oil From Brake Valve From Brake Valve From Hydraulic System Manifold Port BC From Hydraulic Reservoir To Hydraulic Reservoir From Hydraulic System Manifold Port MP4 To Hydraulic Reservoir From Hydraulic System Manifold Port AS To Hydraulic Return Manifold To LSP Shuttle Valve To Hydraulic Return Manifold To Hydraulic Reservoir To Hydraulic Return Manifold To Hydraulic Reservoir Park Brake Pressure Switch Rear Axle Pressure Sensor Front Axle Differential Lock Pressure Sensor Middle Axle Differential Lock Pressure Sensor Rear Axle Differential Lock Pressure Sensor Front Axle Temperature Sensor Middle Axle Temperature Sensor Rear Axle Temperature Sensor Front Axle Pressure Sensor Middle Axle Pressure Sensor Front Axle Filter Restriction Switch Middle Axle Filter Restriction Switch Rear Axle Filter Restriction Switch Left Side Fan Speed Solenoid Right Strut Up Solenoid Right Strut Down Solenoid Left Strut Up Solenoid Left Strut Down Solenoid Park Brake Release Solenoid 2 Park Brake Release Solenoid 1 Left Side Fan Load Sense Relief Solenoid Left Side Reversing Fan Solenoid Section 9025 page 29
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Section 9025 - HYDRAULIC SYSTEM
Y52 Y53 Y54 Y55 Y56 Y57
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Group 15: Diagnostic Information
Front Axle Differential Lock Apply Solenoid Middle Axle Differential Lock Apply Solenoid Rear Axle Differential Lock Apply Solenoid Front Axle Differential Lock Pressure Regulating Solenoid Middle Axle Differential Lock Pressure Regulating Solenoid Rear Axle Differential Lock Pressure Regulating Solenoid
Section 9025 page 30
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Hydraulic System Schematic (3 of 3) (S.N. 668587— )
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Section 9025 page 31
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LEGEND: 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 600 604 606 609 614 701 702 703 704 705 706 707 708 709 710 711 712 713 714 B15 B55 B58 B59 B60 B61 B62 B63 B64 B65 B67 B68 B69 Y9 Y38 Y39 Y40 Y41 Y45 Y46 Y48 Y50 Y52 <- Go to Section TOC
Group 15: Diagnostic Information
Park Brake Manifold Park Brake Release Piston Front Axle Cooling Pump Left Side Fan Pump Left Strut Accumulator Left Strut Active Suspension Manifold Right Strut Right Strut Accumulator Front Axle Cooling Manifold Front Axle Oil Cooler Differential Lock (3 used) Service Brake Piston (4 used) Front Axle Axle Cooling Hydraulic Motor Middle Axle Cooling Pump Rear Axle Cooling Pump Middle Axle Cooling Manifold Middle Axle Oil Cooler Middle Axle Rear Axle Cooling Manifold Rear Axle Left Side Fan Motor (non-reversing) Left Side Fan Motor (optional reversing) High-Pressure Oil Return Oil Trapped Oil Pilot Oil Load Sense Oil From Brake Valve From Brake Valve From Hydraulic System Manifold Port BC From Hydraulic Reservoir To Hydraulic Reservoir From Hydraulic System Manifold Port MP4 To Hydraulic Reservoir From Hydraulic System Manifold Port AS To Hydraulic Return Manifold To LSP Shuttle Valve To Hydraulic Return Manifold To Hydraulic Reservoir To Hydraulic Return Manifold To Hydraulic Reservoir Park Brake Pressure Switch Rear Axle Pressure Sensor Front Axle Differential Lock Pressure Sensor Middle Axle Differential Lock Pressure Sensor Rear Axle Differential Lock Pressure Sensor Front Axle Temperature Sensor Middle Axle Temperature Sensor Rear Axle Temperature Sensor Front Axle Pressure Sensor Middle Axle Pressure Sensor Front Axle Filter Restriction Switch Middle Axle Filter Restriction Switch Rear Axle Filter Restriction Switch Left Side Fan Speed Solenoid Right Strut Up Solenoid Right Strut Down Solenoid Left Strut Up Solenoid Left Strut Down Solenoid Park Brake Release Solenoid 2 Park Brake Release Solenoid 1 Left Side Fan Load Sense Relief Solenoid Left Side Reversing Fan Solenoid Front Axle Differential Lock Apply Solenoid Section 9025 page 32
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Section 9025 - HYDRAULIC SYSTEM
Y53 Y54 Y55 Y56 Y57
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Group 15: Diagnostic Information
Middle Axle Differential Lock Apply Solenoid Rear Axle Differential Lock Apply Solenoid Front Axle Differential Lock Pressure Regulating Solenoid Middle Axle Differential Lock Pressure Regulating Solenoid Rear Axle Differential Lock Pressure Regulating Solenoid
Section 9025 page 33
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Group 15: Diagnostic Information
Hydraulic System Component Location
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Section 9025 page 34
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Steering and Hydraulic Oil Cooling Circuit Component Location
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Section 9025 page 35
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Section 9025 - HYDRAULIC SYSTEM
LEGEND: 1 2 3 6 7 10 11 12 13 17
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Group 15: Diagnostic Information
Secondary Steering Pump Main Hydraulic Pump Attenuator Hydraulic Reservoir Hydraulic Return Manifold Hydraulic Return Filter Hydraulic Oil Cooler Orbital Steering Valve Steering Cylinder (2 used) Hydraulic System Manifold
Section 9025 page 36
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Service Brake and Park Brake Circuit Component Location
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Section 9025 page 37
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LEGEND: 14 15 17 18 19 23 24 35 36 42
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Group 15: Diagnostic Information
Front Axle Brake Accumulator Middle Axle Brake Accumulator Hydraulic System Manifold Electronic Brake Valve Brake Valve Park Brake Manifold Park Brake Release Piston Service Brake Piston Front Axle Middle Axle
Section 9025 page 38
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Cooling Fan and Cab Tilt Circuit Component Location
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Section 9025 page 39
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Section 9025 - HYDRAULIC SYSTEM
LEGEND: 2 3 5 6 7 8 9 10 17 25 26 46
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Group 15: Diagnostic Information
Main Hydraulic Pump Attenuator Right Side Fan Motor Hydraulic Reservoir Hydraulic Return Manifold Cab Tilt Manifold Cab Tilt Cylinder Hydraulic Return Filter Hydraulic System Manifold Front Axle Coolant Pump Left Side Fan Pump Left Side Fan Motor
Section 9025 page 40
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Axle Cooling, Differential Lock, and Active Suspension Circuit Component Location
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Section 9025 page 41
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Section 9025 - HYDRAULIC SYSTEM
LEGEND: 17 25 27 28 29 30 31 32 33 34 36 37 38 39 40 41 42 43 44
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Group 15: Diagnostic Information
Hydraulic System Manifold Front Axle Coolant Pump Left Strut Accumulator Left Strut Active Suspension Manifold Right Strut Right Strut Accumulator Front Axle Cooling Manifold Front Axle Oil Cooler Differential Lock Front Axle Axle Cooling Hydraulic Motor Middle Axle Cooling Pump Rear Axle Cooling Pump Middle Axle Cooling Manifold Middle Axle Oil Cooler Middle Axle Rear Axle Cooling Manifold Rear Axle
Section 9025 page 42
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Dump Body Circuit Component Location
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Section 9025 page 43
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Group 15: Diagnostic Information
LEGEND: 2 Main Hydraulic Pump 3 Attenuator 7 Hydraulic Return Manifold 17 Hydraulic System Manifold 22 Dump Body Cylinder (2 used) No Hydraulic Functions 73
No Hydraulic Functions Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTC) using one of the following methods: Monitor Menus: See CAN Monitor Unit (CMU)—CCU Readings . (9015-16.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any diagnostic trouble codes (DTC) present?
Result: YES:Repair malfunction causing diagnostic trouble code. NO:Go to Hydraulic Oil Level Check. ( 2 ) Hydraulic Oil Level Check
Action: Check hydraulic oil level in reservoir. See Hydraulic System Oil . (Operator′s Manual.) Is oil at correct level?
Result: YES:Go to Main Hydraulic Pump Check. NO:Add oil as necessary. ( 3 ) Main Hydraulic Pump Check
Action: Check pump drive shaft. Is pump turning?
Result: YES:Checks complete. NO:Replace pump. See Main Hydraulic Pump Remove and Install . (Group 2160.)
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Group 15: Diagnostic Information
All Hydraulic Functions Slow 73
All Hydraulic Functions Slow Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any diagnostic trouble codes (DTC) present?
Result: YES:Repair malfunction causing diagnostic trouble code. NO:Go to Hydraulic Oil Level Check. ( 2 ) Hydraulic Oil Level Check
Action: Check hydraulic oil level in reservoir. See Hydraulic System Oil . (Operator′s Manual.) Is oil at correct level?
Result: YES:Go to Cold Hydraulic Oil Check. NO:Add oil as necessary. ( 3 ) Cold Hydraulic Oil Check
Action: Check hydraulic oil temperature. Is hydraulic oil at operating temperature?
Result: YES:Go to Wrong Oil in System Check. NO: Perform Hydraulic System Warmup Procedure . (Group 9025-25.) ( 4 ) Wrong Oil in System Check
Action: Check hydraulic oil. Is recommended hydraulic oil being used?
Result: YES:Go to Engine Speed Check. NO:Replace hydraulic oil. See Hydraulic System Oil . (Operator′s Manual.) ( 5 ) Engine Speed Check
Action: Check engine idle speeds. See Engine Slow and Fast Idle Speed Check . (Group 9010-25.) Are slow and fast idle to specification?
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Group 15: Diagnostic Information
Result: YES:Go to Dump Body Control Valve Check. NO:Diagnose engine. ( 6 ) Dump Body Control Valve Check
Action: Check dump body control valve operation. Is dump body control valve operating correctly?
Result: YES:Go to Pump Suction Line Check. NO:Replace control valve. See Hydraulic System Manifold Disassemble and Assemble . (Group 2160.) ( 7 ) Pump Suction Line Check
Action: Check suction line for air leaks. Are air bubbles in the oil?
Result: YES:Tighten clamps; replace O-rings as necessary. NO:Go to Main Hydraulic Pump Check. ( 8 ) Main Hydraulic Pump Check
Action: Check pump for wear or damage. Is pump worn or damaged?
Result: YES:Replace pump. See Main Hydraulic Pump Remove and Install . (Group 2160.) NO:Checks complete.
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Group 15: Diagnostic Information
Hydraulic Oil Overheats 73
Hydraulic Oil Overheats Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any diagnostic trouble codes (DTC) present?
Result: YES:Repair malfunction causing diagnostic trouble code. NO:Go to Hydraulic Oil Level Check. ( 2 ) Hydraulic Oil Level Check
Action: Check hydraulic oil level in reservoir. See Hydraulic System Oil . (Operator′s Manual.) Is oil at correct level?
Result: YES:Go to Oil Cooler Check. NO:Add oil as necessary. ( 3 ) Oil Cooler Check
Action: Check oil cooler fins for blockage from debris. Are cooling fins blocked?
Result: YES:Clean oil cooler fins. NO:Go to Wrong Oil in System Check. ( 4 ) Wrong Oil in System Check
Action: Check hydraulic oil. Is recommended hydraulic oil being used?
Result: YES:Go to Hydraulic Oil Return Filter Check. NO:Replace hydraulic oil. See Hydraulic System Oil . (Operator′s Manual.) ( 5 ) Hydraulic Oil Return Filter Check
Action: Check oil return filter. Is oil return filter plugged?
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Group 15: Diagnostic Information
Result: YES:Replace filter. See Replace Hydraulic System Return Filter . (Operator′s Manual.) NO:Go to rake Accumulator Charge Valve Check. ( 6 ) Brake Accumulator Charge Valve Check
Action: Check accumulator charge valve pressure. Perform Service Brake Accumulator Charge Valve Test and Adjustment . (Group 9025-25.) Is pressure setting correct?
Result: YES:Go to Cylinder Leakage Check. NO:Adjust charge valve as necessary. ( 7 ) Cylinder Leakage Check
Action: Check cylinders for hot spots indicating oil bypassing piston. Are there cylinder hot spots?
Result: YES: Perform Steering Cylinder Leakage Test (Group 9025-25) or see Dump Body Lift Cylinder Disassemble and Assemble . (Group 3560.) NO:Go to Main Hydraulic Pump Check. ( 8 ) Main Hydraulic Pump Check
Action: Check pump for wear or damage. Is pump worn or damaged?
Result: YES:Replace pump. See Main Hydraulic Pump Remove and Install . (Group 2160.) NO:Checks complete. Main Hydraulic Pump Noisy 73
Main Hydraulic Pump Noisy Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any diagnostic trouble codes (DTC) present?
Result: YES:Repair malfunction causing diagnostic trouble code. NO:Go to Hydraulic Oil Level Check. ( 2 ) Hydraulic Oil Level Check
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Group 15: Diagnostic Information
Action: Check hydraulic oil level in reservoir. See Hydraulic System Oil . (Operator′s Manual.) Is oil at correct level?
Result: YES:Go to Wrong Oil in System Check. NO:Add oil as necessary. ( 3 ) Wrong Oil in System Check
Action: Check hydraulic oil. Is recommended hydraulic oil being used?
Result: YES:Go to Pump Suction Line Check. NO:Replace hydraulic oil. See Change Hydraulic Oil . (Operator′s Manual.) ( 4 ) Pump Suction Line Check
Action: Check suction line for air leaks. Are air bubbles in the oil?
Result: YES:Tighten clamps; replace O-rings as necessary. NO:Replace hydraulic pump. See Main Hydraulic Pump Remove and Install . (Group 2160.)
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Group 15: Diagnostic Information
Dump Body Will Not Rise 73
Dump Body Will Not Rise Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Menus: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any diagnostic trouble codes (DTCs) present?
Result: YES:Repair malfunction causing diagnostic trouble code. NO:Go to next check. ( 2 ) Operator and Owner Body Height Limit Option Check
Action: Check operator and owner body height limit option settings. See CAN Monitor Unit (CMU)—Site Limits . (Group 9015-16.) Are these options enabled?
Result: YES:Disable them and check if dump body will raise. If dump body raises, re-enable body height limits and set new body height limit. NO:Go to next check. OK: ( 3 ) Pilot Pressure Check
Action: Check dump body pilot pressure. See Dump Body Pilot Pressure Test and Adjustment . (Group 9025-25.) Is pressure setting correct?
Result: YES:Go to next check. NO:Adjust pilot pressure and retest. ( 4 ) Main Hydraulic Pump Margin and Maximum Pressure Check
Action: Check the margin and maximum pressure of the main pump settings. Perform Main Hydraulic Pump Margin and Maximum Pressure Test and Adjustment . (Group 9025-25.) Is pressure setting correct?
Result: YES:Go to next check. NO:Adjust pump maximum pressure adjustment valve and pump margin pressure adjustment valve as necessary. ( 5 ) System and Dump Body Raise Relief Valve Check
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Group 15: Diagnostic Information
Action: Check system and dump body raise relief valve pressure settings. Are relief valve settings correct?
Result: YES:Go to next check. NO:If system relief valve pressure is low, replace system relief valve. If pressure is still low, replace dump body raise circuit relief valve. See Hydraulic System Manifold Disassemble and Assemble . (Group 2160.) ( 6 ) Service Brake Accumulator Pressure Regulator Valve Check
Action: Check the service brake accumulator pressure regulator valve pressure settings. Perform Service Brake Accumulator Pressure Regulator Valve Test and Adjustment . (Group 9020-25.) Are service brake accumulator regulator valve settings correct?
Result: YES:Go to next check. NO:If service brake accumulator pressure regulator valve cannot be adjusted to specification, repair or replace valve and repeat test. See Hydraulic System Manifold Remove and Install . (Group 2160.) ( 7 ) Service Brake Accumulator Charge Valve Check
Action: Check the service brake accumulator charge valve pressure settings. Perform Service Brake Accumulator Charge Valve Test and Adjustment . (Group 9020-25.) Are service brake accumulator charge valve settings correct?
Result: YES:Checks complete. NO:If service brake accumulator charge valve cannot be adjusted to specification, repair or replace valve and repeat test. See Hydraulic System Manifold Remove and Install . (Group 2160.)
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Onboard Weighing (OBW) Does Not Function Properly 73
Onboard Weighing (OBW) Does Not Function Properly Diagnostic Procedure Additional References: For additional information, see Onboard Weighing (OBW) Controller Circuit Theory of Operation . (Group 9015-15.) ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTC) using one of the following methods: Monitor Menus: See CAN Monitor Unit (CMU)—CCU Readings . (9015-16.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any diagnostic trouble codes (DTC) present?
Result: YES:Repair malfunction causing diagnostic trouble code. NO:Go to Controller Check. ( 2 ) Controller Check
Action: →NOTE: This check is used to check for communication between on board weighing (OBW) controller, chassis control unit (CCU), and the CAN monitor unit (CMU). Is a weight displayed on the CMU?
Result: YES:Go to Voltage Check. NO: Go to CAN Circuit Check . ( 3 ) Voltage Check
Action: Ignition OFF. Disconnect OBW controller (A18). See On Board Weighing (OBW) and Tire Pressure Monitoring (TPM) System Harness (W11) Component Location. (Group 9015-10.) Ignition ON. Check for voltage between pin 4 and ground (pin 3). Is system voltage (approximately 24 volts) present?
Result: YES:Go to CAN Circuit Check. NO:Check wiring harness. Repair or replace harness. See On Board Weighing (OBW) and Tire Pressure Monitoring (TPM) System Harness (W11) Wiring Diagram. (Group 9015-10.) See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) see Articulation Harness (W9) Wiring Diagram . (Group 9015-10.) see Rear Frame Harness (W10) Wiring Diagram. (Group 9015-10.) ( 4 ) CAN Circuit Check
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Action: Test controller area network (CAN) circuit. See Controller Area Network (CAN) Circuit Test . (Group 9015-20.) Does CAN circuit test good?
Result: YES:Go to Resistance Check. NO:Repair CAN circuit. ( 5 ) Resistance Check
Action: Ignition OFF. Disconnect OBW controller connector (A18). See On Board Weighing (OBW) and Tire Pressure Monitoring (TPM) System Harness (W11) Component Location. (Group 9015-10.) Check resistance between pin 11 and pins 1 and 2 of OBW controller connector (A18). Check resistance between pin 12 and pins 1 and 2 of OBW controller connector (A18). Are approximately 90 ohms present?
Result: YES:Continue check. NO:Repair or replace wiring harness. See On Board Weighing (OBW) and Tire Pressure Monitoring (TPM) System Harness (W11) Wiring Diagram. (Group 9015-10.)
Action: Check resistance between pin 1 and pin 2 of OBW controller connector (A18). Are approximately 120 ohms present?
Result: YES:Continue check. NO:Repair or replace wiring harness. See On Board Weighing (OBW) and Tire Pressure Monitoring (TPM) System Harness (W11) Wiring Diagram. (Group 9015-10.)
Action: Disconnect left and right strain gauge connectors (X27 and X28). Check resistance between pin 1 and pins 2 and 3 of left and right strain gauges (X27 and X28). Are approximately 120 ohms present?
Result: YES:Continue check. NO:Replace strain gauge. See Strain Gauge Remove and Install . (Group 0242.)
Action: Check resistance between pin 2 and pin 3 of left and right strain gauges (X27 and X28). Are approximately 240 ohms present?
Result: YES:If all resistance checks are good but the weight on the CMU still fluctuates, the strain gauge might be malfunctioning. Go <- Go to Section TOC
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
to Left Strain Gauge Check. NO:Replace strain gauge. See Strain Gauge Remove and Install . (Group 0242.) ( 6 ) Left Strain Gauge Check
Action: Ignition OFF. Connect right strain gauge connector (X28) and OBW controller connector (A18). See On Board Weighing (OBW) and Tire Pressure Monitoring (TPM) System Harness (W11) Component Location. (Group 9015-10.) Connect JDG11414 OBW Strain Gauge to left strain gauge connector (X27) to simulate the strain gauge. Ignition ON. Does the weight still fluctuate on the CMU?
Result: YES:Go to Right Strain Gauge Check. NO:Left strain gauge malfunction. Replace left strain gauge. See Strain Gauge Remove and Install . (Group 0242.) ( 7 ) Right Strain Gauge Check
Action: Ignition OFF. Connect left strain gauge connector (X27) and OBW controller (A18). See On Board Weighing (OBW) and Tire Pressure Monitoring (TPM) System Harness (W11) Component Location. (Group 9015-10.) Connect JDG11414 OBW Strain Gauge to right strain gauge connector (X28) to simulate the strain gauge. Ignition ON. Does the weight still fluctuate on the CMU?
Result: YES:Replace OBW controller. See Electronic Controllers Remove and Install . (Group 9015-20.) NO:Right strain gauge malfunction. Replace right strain gauge. See Strain Gauge Remove and Install . (Group 0242.) ( 8 ) OBW Calibration Check
Action: Calibrate OBW system. See On Board Weighing (OBW) Calibration . (Group 9015-20.) Is OBW functioning properly after calibration?
Result: YES:Checks complete. NO:Go to OBW System Accuracy Check. ( 9 ) OBW System Accuracy Check
Action: Check that conditions required for OBW system accuracy are met. See Onboard Weighing (OBW) Controller Circuit Theory of Operation . (Group 9015-15.) Are all required conditions met?
Result: YES:Go to Dump Body Lowered Check. NO:Adjust operation to meet all required conditions. <- Go to Section TOC
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
( 10 ) Dump Body Lowered Check
Action: Fully lower dump body and check dump body percent using CMU. See CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) Does dump body percent display 0%?
Result: YES:Checks complete. NO:Calibrate dump body position sensor. See Dump Body Position Sensor Calibration . (Group 9015-20). OK:
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Hydraulic Fan Motor Not Working 73
Hydraulic Fan Motor Not Working Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any diagnostic trouble codes (DTCs) present?
Result: YES:Repair malfunction causing diagnostic trouble code. NO:Go to Fan Drive Solenoid Valve Check. ( 2 ) Fan Drive Solenoid Valve Check
Action: Check fan cut-off solenoid (Y11) for right side fan or check fan speed solenoid (Y9) for left side fan. See Fan Drive System Operation (Group 9025-05) and see Electrical Component specifications . (Group 9015-20.) Is fan cut-off solenoid valve or fan speed solenoid valve stuck or not working properly?
Result: YES:Repair or replace fan cut-off solenoid valve or fan speed solenoid valve as necessary. NO:Go to Fan Low Pressure Solenoid Valve Check. ( 3 ) Fan Low Pressure Solenoid Valve Check
Action: Check fan low pressure solenoid valves (Y48) and (Y49) for sticking. Is fan low pressure solenoid valve stuck or not working properly?
Result: YES:Repair or replace low pressure solenoid valve as necessary. NO:Go to Fan Relief Valve Check. ( 4 ) Fan Relief Valve Check
Action: Check fan relief valve for sticking. Is fan relief valve stuck open or not working properly?
Result: YES:Repair or replace low pressure solenoid valve as necessary. NO:Go to Fan Reversing Spool Check. ( 5 ) Fan Reversing Spool Check
Action: Check fan reversing spool for sticking. Is fan reversing spool stuck or not working properly?
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Group 15: Diagnostic Information
Result: YES:Repair or replace fan reversing spool as necessary. NO:Go to Hydraulic Fan Motor Check. ( 6 ) Hydraulic Fan Motor Check
Action: Check hydraulic fan motor for sticking. Does hydraulic fan motor spin smoothly without any rough spots?
Result: YES:Checks complete. NO:Repair or replace hydraulic fan motor.
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Group 15: Diagnostic Information
Hydraulic Fan Runs at Full Speed 73
Hydraulic Fan Runs Only at Full Speed Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs) using one of the following methods: Monitor Menus: See CAN Monitor Unit (CMU)—Main Menu—Diagnostics—Codes . (Operator’s Manual.) Service ADVISOR™ Application: See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-15.) Are any diagnostic trouble codes (DTCs) present?
Result: YES:Repair malfunction causing diagnostic trouble code. NO:Go to Temperatures Check. ( 2 ) Temperatures Check
Action: To determine temperatures, see the following: CAN Monitor Unit (CMU)—CCU Readings . (Group 9015-16.) CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) CAN Monitor Unit (CMU)—TCU Readings . (Group 9015-16.) To determine which temperature readings cause fan to operate at full speed, see Hydraulic Fan Control Circuits Theory of Operation . (Group 9015-16.) Are temperature readings causing fan to operate at full speed?
Result: YES:Correct issue causing high temperature. NO: Perform Hydraulic Fan Motor Not Working . (Group 9025-15.) ( 3 ) Exhaust Filter Cleaning Check
Action: To determine if exhaust filter cleaning is active, see Exhaust Aftertreatment Circuit Theory of Operation . (Group 9015-05.) Is exhaust filter cleaning active?
Result: YES:Check complete. NO:Go to Hydraulic Fan Speed Adjustment Check.
Poor or No Service Brakes See Poor or No Service Brakes . (Group 9020-15.)
Service Brake Pads Excessive Wear See Service Brake Pads Excessive Wear . (Group 9020-15.)
Time Between Service Brake Accumulator Charging Cycles Too Short See Time Between Service Brake Accumulator Charging Cycles Too Short . (Group 9020-15.)
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Service Brake Overheats See Service Brake Overheats . (Group 9020-15.)
Service Brake Cooling Oil Leaking See Service Brake Cooling Oil Leaking . (Group 9020-15.)
Service Brake Noise and Vibration See Service Brake Noise and Vibration . (Group 9020-15.)
Service Brakes Do Not Fully Release See Service Brakes Do Not Fully Release . (Group 9020-15.)
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Group 15: Diagnostic Information
Slow or No Steering Function 84
Slow or No Steering Function Diagnostic Procedure ( 1 ) Articulation Locking Bar Check
Action: Check if locking bar is installed. Is locking bar installed?
Result: YES:Remove locking bar and install in storage position. NO:Go to Diagnostic Trouble Code Check. ( 2 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any diagnostic trouble codes (DTC) present?
Result: YES:Repair malfunction causing diagnostic trouble code. NO:Go to Hydraulic Oil Level Check. ( 3 ) Hydraulic Oil Level Check
Action: Check hydraulic oil level in reservoir. See Hydraulic System Oil . (Operator′s Manual.) Is oil at correct level?
Result: YES:Go to Steering Relief Valve Check. NO:Add oil as necessary. ( 4 ) Steering Relief Valve Check
Action: Check steering relief valve. Perform Steering Relief Valve Pressure Test and Adjustment . (Group 9025-25.) Is steering pressure to specification?
Result: YES:Go to Steering Lines Check. NO:Adjust steering relief valve as necessary. ( 5 ) Steering Lines Check
Action: Check if steering lines are crimped or damaged. Are steering lines crimped or damaged?
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Group 15: Diagnostic Information
Result: YES:Replace crimped or damaged steering lines as necessary. NO:Go to Priority Valve Check. ( 6 ) Priority Valve Check
Action: Check priority valve operation. Perform Priority Valve Test . (Group 9025-25.) Is pressure to specification?
Result: YES:Go to Steering Valve Check. NO:Replace priority valve. See Hydraulic System Manifold Disassemble and Assemble . (Group 2160.) ( 7 ) Steering Valve Check
Action: Check steering valve for wear or damage. Is steering valve worn or damaged?
Result: YES:Replace steering valve. See Steering Valve Remove and Install . (Group 0960.) NO:Go to Steering Cylinder Check. ( 8 ) Steering Cylinder Check
Action: Check steering cylinders for leakage. Perform Steering Cylinder Leakage Test . (Group 9025-25.) Is steering cylinder leaking past piston seals?
Result: YES:Replace piston seals. For repair information on 120 series cylinders, see Cylinder Identification . (CTM120519.) NO:Checks complete. Constant Steering Needed to Maintain Straight Travel 84
Constant Steering Needed to Maintain Straight Travel Diagnostic Procedure ( 1 ) Air in Steering System Check
Action: Check for damaged lines and loose fittings. Are lines damaged or fittings loose?
Result: YES:Tighten loose fittings and replace damaged lines. NO:Go to Hydraulic Oil Level Check. ( 2 ) Hydraulic Oil Level Check
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Group 15: Diagnostic Information
Action: Check hydraulic oil level in reservoir. See Check Hydraulic System Oil Level . (Operator′s Manual.) Is oil at correct level?
Result: YES:Go to Steering Cylinder Piston Seals Check. NO:Add oil as necessary. ( 3 ) Steering Cylinder Piston Seals Check
Action: Check steering cylinders for leakage. Perform Steering Cylinder Leakage Test . (Group 9025-25.) Are steering cylinder seal leaking?
Result: YES:Replace piston seals as necessary. For repair information on 120 series cylinders, see Cylinder Identification . (CTM120519.) NO:Go to Steering Valve Check. ( 4 ) Steering Valve Check
Action: Check steering valve for wear or damage. Is steering valve worn or damaged?
Result: YES:Replace steering valve. See Steering Valve Remove and Install . (Group 0960.) NO:Checks complete. Steering Erratic 84
Steering Erratic Diagnostic Procedure ( 1 ) Air in Steering System Check
Action: Check for damaged lines and loose fittings. Are lines damaged or fittings loose?
Result: YES:Tighten loose fittings and replace damaged lines. NO:Go to Hydraulic Oil Level Check. ( 2 ) Hydraulic Oil Level Check
Action: Check hydraulic oil level in reservoir. See Check Hydraulic System Oil Level . (Operator′s Manual.) Is oil at correct level?
Result: YES:Go to Steering Cylinder Piston Loose Check. NO:Add oil as necessary. <- Go to Section TOC
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Group 15: Diagnostic Information
( 3 ) Steering Cylinder Piston Loose Check
Action: Check steering cylinder piston. For repair information on 120 series cylinders, see Cylinder Identification . (CTM120519.) Is steering cylinder piston loose?
Result: YES:Tighten steering cylinder piston nut. NO:Go to Steering Valve Check. ( 4 ) Steering Valve Check
Action: Check steering valve for wear or damage. Is steering valve worn or damaged?
Result: YES:Replace steering valve. See Steering Valve Remove and Install . (Group 0960.) NO:Checks complete. Steering Soft or Spongy 84
Steering Soft or Spongy Diagnostic Procedure ( 1 ) Air in Steering System Check
Action: Check for damaged lines and loose fittings. Are lines damaged or fittings loose?
Result: YES:Tighten loose fittings and replace damaged lines. NO:Go to Hydraulic Oil Level Check. ( 2 ) Hydraulic Oil Level Check
Action: Check hydraulic oil level in reservoir. See Hydraulic Oil . (Operator′s Manual.) Is oil at correct level?
Result: YES:Checks complete. NO:Add oil as necessary. Steering Wheel Free Play 84
Steering Wheel Free Play Diagnostic Procedure ( 1 ) Steering Wheel Shaft Nut Check
Action: Check steering wheel shaft nut. Is shaft nut loose? <- Go to Section TOC
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Group 15: Diagnostic Information
Result: YES:Tighten shaft nut. NO:Go to Steering Shaft Splines Check. ( 2 ) Steering Shaft Splines Check
Action: Check steering shaft and steering valve splines for wear or damage. Are shaft or valve splines worn or damaged?
Result: YES:Replace steering valve. See Steering Valve Remove and Install . (Group 0960.) NO:Checks complete.
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Group 15: Diagnostic Information
Steering Locks Up 84
Steering Locks Up Diagnostic Procedure ( 1 ) Diagnostic Trouble Code Check
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any diagnostic trouble codes (DTC) present?
Result: YES:Repair malfunction causing diagnostic trouble code. NO:Go to Hydraulic Oil Level Check. ( 2 ) Hydraulic Oil Level Check
Action: Check hydraulic oil level in reservoir. See Hydraulic System Oil . (Operator′s Manual.) Is oil at correct level?
Result: YES:Go to Steering Relief Valve Check. NO:Add oil as necessary. ( 3 ) Steering Relief Valve Check
Action: Check steering relief valve. Perform Steering Relief Valve Pressure Test and Adjustment . (Group 9025-25.) Is steering pressure to specification?
Result: YES:Go to Steering Lines Check. NO:Adjust steering relief valve as necessary. ( 4 ) Steering Lines Check
Action: Check if steering lines are crimped or damaged. Are steering lines crimped or damaged?
Result: YES:Replace crimped or damaged steering lines as necessary. NO:Go to Priority Valve Check. ( 5 ) Priority Valve Check
Action: Check priority valve operation. Perform Priority Valve Test . (Group 9025-25.) Is pressure to specification?
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Section 9025 - HYDRAULIC SYSTEM
Group 15: Diagnostic Information
Result: YES:Go to Steering Valve Check. NO:Replace priority valve. See Hydraulic System Manifold Disassemble and Assemble . (Group 2160.) ( 6 ) Steering Valve Check
Action: Check steering valve for wear or damage. Is steering valve worn or damaged?
Result: YES:Replace steering valve. See Steering Valve Remove and Install . (Group 0960.) NO:Go to Steering Cylinder Check. Steering Wheel Turns by Itself 84
Steering Wheel Turns by Itself Diagnostic Procedure ( 1 ) Line-to-Port Connection Check
Action: Check steering valve line connections. See Hydraulic System Schematic . (Group 9025-15.) Are lines connected to the correct steering valve ports?
Result: YES:Check complete. NO:Connect steering lines to correct steering valve ports. Machine Turns in Opposite Direction as Steering Wheel 84
Machine Turns in Opposite Direction as Steering Wheel Diagnostic Procedure ( 1 ) Steering Valve-to-Steering Cylinder Lines Check
Action: Check steering valve-to-steering cylinder lines. See Hydraulic System Schematic . (Group 9025-15.) Are steering cylinder lines connected to the correct steering valve ports?
Result: YES:Check complete. NO:Connect steering cylinder lines to correct steering valve ports. Machine Turns With Steering Valve in Neutral 84
Machine Turns With Steering Valve in Neutral Diagnostic Procedure ( 1 ) Steering Valve Check
Action: Check steering valve for wear or damage. Is steering valve worn or damaged?
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Group 25: Test
Result: YES:Replace steering valve. See Steering Valve Remove and Install . (Group 0960.) NO:Check complete.
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Group 25: Test
Group 25 - Test JT02156A Digital Pressure/Temperature Analyzer Kit Installation LEGEND: 1 JT02158 Digital Pressure/Temperature Analyzer 2 JT02161 Transducer 3500 kPa (35 bar) (500 psi) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi)
JT02158 Digital Pressure/Temperature Analyzer and Transducers Service Equipment and Tools JT02156A Digital Pressure/Temperature Analyzer Kit JT02158 Digital Pressure/Temperature Analyzer JT02159 6.1 m (20 ft.) Cable with Couplers JT02161 Transducer 3500 kPa (35 bar) (500 psi) JT02162 Transducer 35 000 kPa (350 bar) (5000 psi) JT02166 Compression Test Adapter 235400 Thermo-Coupler 312883 Carry Case
JT02160 Transducer 70 000 kPa (700 bar) (10 000 psi) (ordered separately) →NOTE: It is recommended that D05200ST Hydraulic Gauge Protector and Snubber be used with JT02161 to possibly protect and extend the life of the product. Hydraulic Gauge Protector and Snubber D05200ST Protect gauges in diagnostic test kits, 0-600 plus/minus 30 psi. Use the JT02158 Digital Pressure/Temperature Analyzer (1) in place of analog gauges and a separate temperature reader. Digital Pressure/Temperature Analyzer JT02158 Used to check hydraulic pressure and temperature. Transducers (2) are temperature sensitive. Allow transducer to warm to system temperature. After it is warmed and no pressure applied, push sensor zero button for 1 second to set the true zero point. Transducer 3500 kPa (35 bar) (500 psi) JT02161 Used to check hydraulic pressure and temperature. Transducer 35 000 kPa (350 bar) (5000 psi) JT02162 Used to check hydraulic pressure and temperature. When different pressures are used, turn selector to the OFF position for 2 seconds and then to the selected pressure range. <- Go to Section TOC
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Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Readings will be inaccurate if the proper range for transducer is not used.
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Group 25: Test
Hydraulic System Warmup Procedure IMPORTANT: If machine temperature is below -18° C (0° F), start procedure with engine running at 1/2 speed. Failure to do this could cause pump cavitation. Once oil temperature is above -18° C (0° F), the engine speed can be increased to fast idle. Below -18° C (0° F) an extended warmup period may be necessary. Hydraulic function will move slowly and lubrication of parts may not be adequate with cold oil. Do not attempt normal machine operation until hydraulic functions move at or close to normal cycle times. Operate functions slowly and avoid sudden movements until engine and hydraulic oils are thoroughly warmed. Operate a function by moving it a short distance in each direction. Continue operating the function, increasing the distance traveled in each cycle until full stroke is reached. For faster warmup, restrict air flow through oil cooler using cardboard or other similar material. Use correct viscosity hydraulic oil to minimize warmup period. For correct hydraulic oil, see Hydraulic System Oil . (Operator′s Manual.) [1] - Display hydraulic oil temperature using the CAN monitor unit (CMU). See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) [2] CAUTION: Avoid possible serious injury from machine movement during warmup procedure. Clear the area of all bystanders before doing the warmup procedure. Clear the area of all bystanders to allow for machine movement. [3] - Start engine. Do not accelerate engine rapidly during warmup. Run engine at 1/2 speed for approximately 5 minutes before operating any functions. [4] - Engage park brake. [5] - Activate Service Mode. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [6] IMPORTANT: Holding a function in relief for more than 10 seconds can cause damage to control valve. IMPORTANT: Avoid damage to machine frame. Do not steer machine back and forth with articulation lock bar in place. Operate steering and dump body raise and lower functions in relief to heat hydraulic system. [7] - Once oil temperature is above -18° C (0° F), increase engine speed to fast idle. [8] - Stop periodically and operate all hydraulic functions to distribute the heated oil. [9] - Continue operating steering and dump body until operating temperature is reached. Item
Measurement
Specification
Normal Operating Temperature
Temperature
60—70° C 140—160° F
[10] - Turn machine off after warmup is complete to deactivate CMU service mode.
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Group 25: Test
Cycle Time Test Specifications SPECIFICATIONS Hydraulic Oil Temperature
60—71° C 140—160° F
Engine Speed (high idle)
2250 rpm
Dump Body Raise Cycle Time
12—14 sec.
Dump Body Lower Cycle Time
7.5—9.55 sec.
Steering Wheel Stop-to-Stop Cycle Time
4.5—5.5 sec.
Steering Wheel Stop-to-Stop Turns
4.7
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Stopwatch
Test is used as an indication of hydraulic circuit performance. A slow cycle time is an indication of a restriction or leakage in that circuit. Cycle times are also a general indication of hydraulic pump performance. Always record the average of at least three complete cycle times. [1] - Heat hydraulic oil to specified temperature. See Hydraulic System Warmup Procedure . (Group 9025-25.) Use monitor display unit to monitor hydraulic oil temperature. See CAN Monitor Unit (CMU)—Main Menu . (Operator′s Manual.) Item
Measurement
Specification
Hydraulic Oil
Temperature
60—71° C 140—160° F
[2] CAUTION: Avoid possible serious injury. Clear area of all bystanders before performing test. Do not perform this test within 4 m (13 ft.) of high voltage power lines. →NOTE: To perform these tests, the machine must be parked in an area that will allow the dump body to be raised to full height. Park machine on level ground in an area that will allow the dump body to be raised to full height. [3] - Dump Body —Select N (neutral) on sealed switch module (SSM) and engage park brake. [4] - Operate machine at specification. Item
Measurement
Specification
Engine (high idle)
Speed
2250 rpm
[5] - Actuate dump body control valve to full stroke for each function. Record cycle times. Stop Watch To measure cycle time Item
Measurement
Specification
Dump Body Raise
Cycle Time
12—14 sec.
Dump Body Lower
Cycle Time
7.5—9.5 sec.
[6] - Steering— Select N (neutral) on SSM and disengage park brake. [7] - Operate machine at specification. Item
Measurement
Specification
Engine (high idle)
Speed
2250 rpm
<- Go to Section TOC
Section 9025 page 71
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
[8] - Starting with machine turned against the left or right stop, turn steering wheel to opposite stop. Record the time and number of steering wheel turns stop-to-stop. Repeat several times, in both directions, to verify count. Item
Measurement
Specification
Steering Wheel Stop-to-Stop
Cycle Time
3.5—5.5 sec.
Steering Wheel Stop-to-Stop
Turns
4.7
<- Go to Section TOC
Section 9025 page 72
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Main Hydraulic Pump Margin and Maximum Pressure Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature
60—71° C 140—160° F
Engine Speed (slow idle)
900 rpm
Main Hydraulic Pump Margin Pressure
2999—3206 kPa 30—32 bar 435—465 psi
Main Hydraulic Pump Maximum Pressure—370E/410E
24 700—25 300 kPa 247—253 bar 3582—3669 psi
Main Hydraulic Pump Maximum Pressure—460E
26 700—27 300 kPa 267—273 bar 3873—3960 psi
Essential Tools ESSENTIAL TOOLS JT03482 High Pressure Test Hose Kit
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure/Temperature Analyzer JT03482 High Pressure Test Hose Kit
The purpose of this test is to check the margin and maximum pressure of the main pump settings and adjust as necessary. CAUTION: Avoid possible serious injury. Clear area of all bystanders before performing test. Do not perform this test within 4 m (13 ft.) of high voltage power lines. IMPORTANT: To perform these tests, the machine must be parked in an area that will allow the dump body to be raised to full height. [1] LEGEND: 1 Main Pump (PM) 2 Steering (OM) 3 Brake Charge (MP4) 4 Dump Body Pilot (PS) 5 Fan Drive Load Sense (LSFD) 6 Main Pump Load Sense (LSPM)
Test Port Manifold Install articulation locking bar. [2] - Connect JT02156A Digital Pressure/Temperature Analyzer and transducer or a gauge, using JT03482 High Pressure Test <- Go to Section TOC
Section 9025 page 73
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Hose Kit, to Main Pump (PM) (1) and Main Pump Load Sense (LSPM) (6) of test port manifold. High Pressure Test Hose Kit JT03482 To connect transducer or gauge to test port manifold. Digital Pressure/Temperature Analyzer JT02156A To read hydraulic pressure. [3] - Perform Hydraulic System Warmup Procedure . (Group 9025-25.) Use CAN monitor unit to monitor hydraulic oil temperature. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Item
Measurement
Specification
Normal Operating Temperature
Temperature
60—70° C 140—160° F
[4] - Main Pressure Setting— Activate Service Mode. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [5] - Go to Diagnostics/Calibrations/Hydraulic/Set Max Pressure. See CAN Monitor Unit (CMU)—Calibrations . (Group 9015-16.) [6] - Raise dump body until cylinders are fully extended and hold in relief. [7] CAUTION: Beware of rotating drive shaft when making adjustment on main hydraulic pump. Keep all tools and equipment stored away from openings so they do not fall into the drive shaft. Wear close fitting clothing. LEGEND: 7 Pump Maximum Pressure Adjustment Valve (P Max) 8 Pump Margin Pressure Adjustment Valve (Delta P)
Rotating Drive Shaft Entanglement (arm)
Main Hydraulic Pump Margin and Max Pressure Adjustment Valves <- Go to Section TOC
Section 9025 page 74
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Operate machine at specification and record hydraulic pump maximum pressure at test port PM. If pressure is not to specification, adjust pump maximum pressure adjustment valve (P Max) (7) on main hydraulic pump as follows: Item
Measurement
Specification
Engine
Speed
900 rpm
Pump Maximum Pressure—370E/410E
Pressure
24 700—25 300 kPa 247—253 bar 3582—3669 psi
Pump Maximum Pressure—460E
Pressure
26 700—27 300 kPa 267—273 bar 3873—3960 psi
a. Loosen adjusting screw lock nut on pump maximum pressure adjustment valve (P Max) (7). b. Turn adjusting screw in to increase pressure or out to decrease pressure. c. Tighten adjusting screw lock nut on pump maximum pressure adjustment valve (P Max) (7). [8] IMPORTANT: To avoid machine damage, pump maximum pressure setting must be set before margin pressure can be set. Margin Pressure Setting— Verify Service Mode is active. See CAN Monitor Unit (CMU)—Service Mode . (Group 9015-16.) [9] - Go to Diagnostics/Calibrations/Hydraulic/Set Margin Pressure. See CAN Monitor Unit (CMU)—Calibrations . (Group 9015-16.) [10] - Operate machine at specification and record margin pressure at test port LSPM and main pump pressure at test port PM (1). Subtract the difference between the two readings and compare to specification. If pressure is not to specification, adjust pump margin pressure adjustment valve (Delta P) (8) on main hydraulic pump as follows: Item
Measurement
Specification
Engine
Speed
900 rpm
Pump Margin Pressure
Pressure
2999—3206 kPa 30—32 bar 435—465 psi
a. Loosen adjusting screw lock nut on pump margin pressure adjustment valve (Delta P) (8). b. Turn adjusting screw in to increase pressure or out to decrease pressure. c. Tighten adjusting screw lock nut on pump margin pressure adjustment valve (Delta P) (8). [11] - Cycle ignition to end hydraulic pressure setup mode and exit Service Mode. [12] - If the margin and maximum pressure cannot be adjusted, inspect and replace pump as necessary and repeat test. See Main Hydraulic Pump Remove and Install . (Group 2160.)
<- Go to Section TOC
Section 9025 page 75
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Dump Body Pilot Pressure Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature
60—71° C 140—160° F
Engine Speed (slow idle)
900 rpm
Dump Body Pilot Pressure
3495 kPa 35 bar 507 psi
Essential Tools ESSENTIAL TOOLS JT03482 High Pressure Test Hose Kit
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure/Temperature Analyzer
The purpose of this test is to check dump body pilot pressure settings. [1] CAUTION: Avoid possible serious injury. Clear area of all bystanders before performing test. Do not perform this test within 4 m (13 ft.) of high voltage power lines. →NOTE: To perform these tests, the machine must be parked in an area that will allow the dump body to be raised to full height. LEGEND: 1 Main Pump (PM) 2 Steering (OM) 3 Brake Charge (MP4) 4 Dump Body Pilot (PS) 5 Fan Drive Load Sense (LSFD) 6 Main Pump Load Sense (LSPM)
Test Port Manifold Connect JT02156A Digital Pressure/Temperature Analyzer and transducer or a gauge, using JT03482 High Pressure Test Hose Kit, to dump body pilot (PS) (4) of test port manifold. High Pressure Test Hose Kit JT03482 To connect transducer or gauge to test port manifold. Digital Pressure and Temperature Analyzer JT02156A To read hydraulic pressure. <- Go to Section TOC
Section 9025 page 76
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
[2] - Perform Hydraulic System Warmup Procedure . (Group 9025-25.) Use CAN monitor unit (CMU) to monitor hydraulic oil temperature. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Item
Measurement
Specification
Hydraulic Oil
Temperature
60—71° C 140—160° F
[3] CAUTION: Rotating drive shaft can cause personal injury, dismemberment or death. To avoid entanglement, wear close fitting clothing and do not make contact with rotating drive shaft. Keep all tools and equipment stored away from openings so they do not fall into drive shaft.
Rotating Drive Shaft Entanglement (arm)
<- Go to Section TOC
Section 9025 page 77
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Hydraulic System Manifold LEGEND: 7 Dump Body Pilot Pressure Adjustment Valve (X4) Raise dump body until cylinders are fully extended and hold in relief. Run engine at specification and record dump body pilot pressure at test port (PS). If pressure is not to specification, adjust dump body pilot pressure adjustment valve (X4) (7) on main hydraulic manifold as follows: Item
Measurement
Specification
Engine
Speed
900 rpm
System Relief Valve
Pressure
3495 kPa 35 bar 507 psi
a. Loosen adjusting screw lock nut on valve X4 (7). b. Turn adjusting screw in to increase pressure or out to decrease pressure. c. Tighten adjusting screw lock nut on valve X4 (7). [4] - If pressure reading is not to specification, replace dump body pilot pressure adjustment valve (X4) (7) and repeat test. If pressure reading is still not to specification, replace dump body raise circuit relief valve.
<- Go to Section TOC
Section 9025 page 78
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Dump Body Manual Lowering & Bin Tip Circuit Pressure Relieving Procedure Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS 7/8 in. Combination Wrench 3/16 in. Hex Key Wrench
The purpose of this procedure is to lower the dump body by turning flow control valve (57) adjusting screw. [1] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 9000-01.) [2] CAUTION: Avoid possible serious injury. Clear area of all bystanders before performing procedure.
Hydraulic System Manifold—Top View LEGEND: 17 Hydraulic System Manifold 57 Flow Control Valve Loosen adjusting screw lock nut on flow control valve (57) using 7/8 in. combination wrench. Combination Wrench 7/8 in. Used to loosen and tighten adjusting screw lock nut. <- Go to Section TOC
Section 9025 page 79
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Hex Key Wrench 3/16 in. Used to loosen and tighten adjusting screw. [3] - SLOWLY turn adjusting screw out counterclockwise using 3/16 in. hex key wrench to lower dump body. [4] - Tighten adjusting screw. [5] - Tighten adjusting screw lock nut. For more information: See Hydraulic System Manifold Operation . (Group 9025-25.) See Hydraulic System Component Location . (Group 9025-15.)
<- Go to Section TOC
Section 9025 page 80
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Priority Valve Test Specifications SPECIFICATIONS Hydraulic Oil Temperature
45—55° C 110—130° F
Engine Speed (slow idle)
900 rpm
The purpose of this test is to verify the operation of the priority valve. [1] - Park machine in an open area having a hard, level surface. [2] CAUTION: Prevent possible injury from unexpected machine movement. Install articulation locking bar before working around frame hinge area. Perform Hydraulic System Warmup Procedure . (Group 9025-25.) Use CAN monitor unit to monitor hydraulic oil temperature. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Item
Measurement
Specification
Normal Operating Temperature
Temperature
60—70° C 140—160° F
[3] - Run engine at specification. Item
Measurement
Specification
Engine
Speed
900 rpm
[4] - Starting with machine perform the bin dump operation and steer fully left to right or right to left. If hydraulics are able to steer the steering over bin dump operation, priority valve is functioning. [5] - If hydraulics are not able to steer while dumping, replace priority valve. See Hydraulic System Manifold Disassemble and Assemble . (Group 2160.)
Service Brake Accumulator Pressure Reducing Valve Test and Adjustment See Service Brake Accumulator Pressure Reducing Valve Test and Adjustment . (Group 9020-25.)
Service Brake Accumulator Charge Valve Test and Adjustment See Service Brake Accumulator Charge Valve Test and Adjustment . (Group 9020-25.)
Service Brake Low Pressure Switch and Service Brake Accumulator Charge Test See Service Brake Low Pressure Switch and Service Brake Accumulator Charge Test . (Group 9020-25.)
Front and Rear Service Brake Accumulators Pressure Test and Charge Procedure See Front and Rear Service Brake Accumulators Pressure Test and Charge Procedure . (Group 9020-25.)
Service Brake Valve Test See Service Brake Valve Test . (Group 9020-25.)
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Section 9025 page 81
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Electronic Brake Valve (EBV) Test See Electronic Brake Valve (EBV) Test . (Group 9020-25.)
Axle Cooling Pump Pressure Test and Flow Test See Axle Cooling Pump Pressure Test and Flow Test . (Group 9020-25.)
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Section 9025 page 82
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Orbital Steering Valve Leakage Test Specifications SPECIFICATIONS Hydraulic Oil Temperature
60—70°C 140—160°F
Engine Speed
Slow Idle
Steering Wheel Torque
11 N·m 100 lb.-in.
Orbital Steering Valve Leakage (maximum)
11 L/min 2.9 gpm
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Test Line Measuring Container
Perform this test to determine leakage rate through orbital steering valve. Excessive leakage can indicate excessive wear of internal orbital steering valve components. [1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 9000-01.) [2] 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. LEGEND: 1 Orbital Steering Valve 2 Orbital Steering Return Line
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Section 9025 page 83
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Orbital Steering Valve Stop engine and relieve hydraulic pressure. [3] - Drain hydraulic reservoir. See Change Hydraulic Oil . (Operator′s Manual.) [4] - Disconnect orbital steering return line (2) near fitting. Plug orbital steering return line. [5] - Connect test line to orbital steering return line. Route test line into hydraulic tank filler and secure hose to circulate oil to reservoir during machine warm-up. Test Line To route steering valve leakage to measuring container. Measuring Container To measure steering valve leakage. [6] - Fill hydraulic reservoir. See 370E, 410E, and 460E Drain and Refill Capacities . (Operator′s Manual.) [7] - Install torque wrench on steering wheel retaining nut. [8] CAUTION: Prevent possible burn injury from hot exhaust components. Disable exhaust filter auto cleaning. Disable exhaust filter auto cleaning. See CAN Monitor Unit (CMU)—Main Menu—Exhaust Filter—Auto Cleaning . (Operator′s Manual.) [9] CAUTION: Prevent possible injury and machine damage from unexpected machine movement. Clear all persons and other machinery from area before steering machine during warm-up procedure. Perform hydraulic oil warm-up procedure while steering machine back and forth to ensure orbital steering valve (1) contains heated oil. See Hydraulic System Warmup Procedure . (Group 9025-25.) Item
Measurement
Specification
Hydraulic Oil
Temperature
60—70°C
<- Go to Section TOC
Section 9025 page 84
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM Item
Group 25: Test Measurement
Specification 140—160°F
[10] - Run engine at specification. Item
Measurement
Specification
Engine
Speed
Slow Idle
[11] - Turn steering wheel clockwise using torque wrench at specified torque for 1 minute. Measure leakage from orbital steering return line and compare to specification. Item
Measurement
Specification
Steering Wheel
Torque
11 N·m
Orbital Steering Valve
Leakage (maximum)
100 lb.-in. 11 L/min 2.9 gpm
[12] - If leakage is greater than specification, replace orbital steering valve and repeat test. See Steering Valve Remove and Install . (Group 0960.) [13] - Enable exhaust filter auto cleaning. [14] - Drain hydraulic reservoir. See Change Hydraulic Oil . (Operator′s Manual.) [15] - Remove test equipment. [16] - Fill hydraulic reservoir. See 370E, 410E, and 460E Drain and Refill Capacities . (Operator′s Manual.) [17] - Remove frame articulation lock bar.
<- Go to Section TOC
Section 9025 page 85
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Steering Relief Valve Pressure Test and Adjustment Specifications SPECIFICATIONS Hydraulic Oil Temperature
60—71° C 140—160° F
Engine Speed (slow idle)
900 rpm
Steering Relief Valve Pressure
23 821—24 442 kPa 238.2—244.4 bar 3455—3545 psi
Essential Tools ESSENTIAL TOOLS JT03482 High Pressure Test Hose Kit
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure/Temperature Analyzer
The purpose of this test is to check the steering load sense relief valve pressure and adjust as necessary. LEGEND: 1 Main Pump (PM) 2 Steering (OM) 3 Brake Charge (MP4) 4 Dump Body Pilot (PS) 5 Fan Drive Load Sense (LSFD) 6 Main Pump Load Sense (LSPM)
Test Port Manifold [1] CAUTION: Prevent possible injury from unexpected machine movement. Install articulation locking bar before working around frame hinge area. Install articulation locking bar. [2] →NOTE: The accuracy of this test and adjustment is dependent on the correct adjustment of the main hydraulic pump. Perform Main Hydraulic Pump Margin and Maximum Pressure Test and Adjustment . (Group 9025-25.) [3] - Connect JT02156A Digital Pressure/Temperature Analyzer and transducer or a gauge, using JT03482 High Pressure Test Hose Kit to steering (OM) (2) of test port manifold. High Pressure Test Hose Kit JT03482 <- Go to Section TOC
Section 9025 page 86
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
To connect transducer or gauge to test port manifold. Digital Pressure/Temperature Analyzer JT02156A To read hydraulic pressure. [4] - Perform Hydraulic System Warmup Procedure . (Group 9025-25.) Use CAN monitor unit to monitor hydraulic oil temperature. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Item
Measurement
Specification
Normal Operating Temperature
Temperature
60—70° C 140—160° F
[5] - Run engine at specification. Item
Measurement
Specification
Engine
Speed
900 rpm
[6] IMPORTANT: Avoid damage to machine frame. Do not steer machine back and forth with articulation lock bar in place. Turn machine left against articulation locking bar to allow steering circuit to go in relief. Record pressure reading. [7] CAUTION: Beware of rotating drive shaft when making adjustment on main hydraulic pump. Keep all tools and equipment stored away from openings so they do not fall into the drive shaft. Wear close fitting clothing.
Rotating Drive Shaft Entanglement (arm)
<- Go to Section TOC
Section 9025 page 87
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Main Hydraulic Manifold LEGEND: 7 Steering Load Sense Relief Valve X1 Record steering load sense relief valve pressure at test port OM. If pressure is not to specification, adjust steering load sense relief valve X1 (7) on main hydraulic manifold as follows: Item
Measurement
Specification
Steering Relief Valve
Pressure
23 821—24 442 kPa 238.2—244.4 bar 3455—3545 psi
a. Loosen adjusting screw lock nut on steering load sense relief valve X1 (7). b. Turn adjusting screw in to increase pressure or out to decrease pressure. c. Tighten adjusting screw lock nut on steering load sense relief valve X1 (7). [8] - If relief valve X1 cannot be adjusted to specification, replace relief valve and repeat test. See Hydraulic System Manifold Remove and Install . (Group 2160.)
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Section 9025 page 88
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Steering Cylinder Leakage Test Specifications SPECIFICATIONS Hydraulic Oil Temperature
60—71° C 140—160° F
Engine Speed (slow idle)
900 rpm
Steering Cylinder Piston Seal Maximum Leakage
15 mL/min. 1/2 oz./min.
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS 0—50 mL Graduated Measuring Container
The purpose of this test is to measure steering cylinder piston seal leakage. [1] - Perform Hydraulic System Warmup Procedure . (Group 9025-25.) Use CAN monitor unit to monitor hydraulic oil temperature. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Item
Measurement
Specification
Normal Operating Temperature
Temperature
60—70° C 140—160° F
[2] →NOTE: Check steering cylinder for leakage in the fully extended position. In retracted position, piston contacts head end of cylinder, blocking leakage flow across piston seal to head end port. Turn machine left or right against steering stop to extend steering cylinder to be checked. Stop the engine. [3] - Disconnect line from rod end port of the extended cylinder. Install a plug in open line. Place a graduated measuring container under open cylinder port to catch leakage. Graduated Measuring Container 0—50 mL Used to measure steering cylinder leakage. [4] - Start engine and run at specification. Item
Measurement
Specification
Engine
Speed
900 rpm
[5] - Turn steering wheel against stop in same direction as machine is turned. Hold against stop for 20 seconds. Record leakage and multiply reading by three. Item
Measurement
Specification
Steering Cylinder Piston Seal Maximum
Leakage
15 mL/min. 1/2 oz./min.
[6] - If leakage is over specification, inspect steering cylinder piston seals. See Steering Cylinder Disassemble and Assemble . (Group 0960.)
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Section 9025 page 89
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Dump Body Heat Diverter Valve Pressure Test Specifications SPECIFICATIONS Hydraulic Oil Temperature
45—55° C 110—130° F
Dump Body Heat Diverter Regulating Valve Pressure
1000—1104 kPa 10—11 bar 145—160 psi
Engine Speed (low idle)
900 rpm
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure/Temperature Analyzer JT07192 Electric Hydraulic Pump -6 M ORFS Plug
The purpose of this test is to verify the pressure setting of the dump body heat diverter pressure regulating valve and adjust as necessary. [1] CAUTION: Prevent possible injury from unexpected machine movement. Install articulation locking bar before working around frame hinge area. →NOTE: To perform this test, machine must be parked in an area that will allow dump body to be raised to full height.
Test Connections and Adjustment <- Go to Section TOC
Section 9025 page 90
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
LEGEND: 1 Pressure Regulating Valve 2 Outlet Port T Install articulation locking bar. [2] - Remove hydraulic line from outlet port T (2) and install JT02156A Digital Pressure/Temperature Analyzer and transducer or a gauge inline with circuit. Digital Pressure and Temperature Analyzer JT02156A To read hydraulic pressure. [3] - Warm hydraulic oil to specification. Perform Hydraulic System Warmup Procedure . (Group 9025-25.) Item
Measurement
Specification
Hydraulic Oil
Temperature
45—55° C 110—130° F
[4] - Start engine and run at specification. Item
Measurement
Specification
Engine (low idle)
Speed
900 rpm
[5] - When pressure stabilizes, record pressure and compare to specification. Item
Measurement
Specification
Dump Body Heat Diverter Regulating Valve
Pressure
1000—1104 kPa 10—11 bar 145—160 psi
[6] - If pressure is not to specification, adjust pressure regulating valve as follows: a. Loosen adjusting screw lock nut on pressure regulating valve (1). b. Turn adjusting screw in to increase pressure or out to decrease pressure. c. Tighten adjusting screw lock nut on pressure regulating valve (1). [7] - Disconnect test equipment and connect hydraulic line. [8] - Remove articulation locking bar. [9] - If pressure regulating valve (1) cannot be adjusted to specification, replace relief valve and repeat test. See Dump Body Heat Diverter Valve Remove and Install . (Group 2160.)
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Section 9025 page 91
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Hydraulic Fan Circuit Flow Test Specifications SPECIFICATIONS Hydraulic Oil Temperature
60—70° C 140—160° F
Engine Speed (slow idle)
900 rpm
Engine Speed (high idle)
2270 rpm
Cooling Fan Circulation Pump Flow Rate—Idle
25 L/min 6 gpm
Cooling Fan Circulation Pump Flow Rate—High Idle
203 L/min 14 gpm
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07148 Digital Hydraulic Flow Meter
The purpose of this test is to verify that there is no restriction in the hydraulic fan circuits and that the hydraulic pumps and hydraulic fan motors are functioning properly. [1] CAUTION: Prevent possible injury from unexpected machine movement. Install articulation locking bar before working around frame hinge area.
→NOTE: The right and left hydraulic fan motors work separately of each other on different hydraulic circuits and pumps. They will both need to be tested to determine individual pump performance. For more information on the hydraulic fan circuit operation, see Fan Drive System Operation . (Group 9025-25.) Park and Prepare for Service Safely . (Group 9000-01.) [2] - Perform Hydraulic System Warmup Procedure . (Group 9025-25.) Use CAN monitor unit to monitor hydraulic oil temperature. See CAN Monitor Unit (CMU)—Main Menu—Diagnostics . (Operator′s Manual.) Item
Measurement
Specification
Normal Operating Temperature
Temperature
60—70° C 140—160° F
[3] →NOTE: The oil supply line and the return line are oriented in different locations between the standard fan motor and the reversing fan motor. Verify what fan motor the machine is equipped with before installing test equipment. Improper setup will result in inaccurate test results.
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Section 9025 page 92
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
Standard Hydraulic Fan Motor (right side fan shown)
Reversing Hydraulic Fan Motor (right side fan shown) LEGEND: 1 Oil Supply Line 2 Hydraulic Fan Motor 3 Return Line to Tank Remove the oil supply line (1) from the hydraulic fan motor (2) and install JT07148 Digital Hydraulic Flow Meter inline with the fan oil supply circuit. See Hydraulic System Component Location . (Group 9025-15.) Digital Hydraulic Flow Meter JT07148 To measure hydraulic fluid flow. [4] -
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Section 9025 page 93
TM12406-OPERATION AND TEST MANUAL
Section 9025 - HYDRAULIC SYSTEM
Group 25: Test
LEGEND: 4 Left Side Fan Pump 5 Left Side Hydraulic Fan Speed Solenoid
Left Side Fan Motor Speed Solenoid Left Side Hydraulic Fan— Disconnect the left side hydraulic fan speed solenoid (5) located on the left side fan pump (4). [5] - Operate engine at slow idle. Record flow and compare to specification. Item
Measurement
Specification
Slow Idle
Speed
900 rpm
Left Fan Hydraulic Pump
Flow Rate
25 L/min 6 gpm
[6] - Operate engine at high idle. Record flow and compare to specification. Item
Measurement
Specification
High Idle
Speed
2270 rpm
Left Fan Hydraulic Pump
Flow Rate
203 L/min 14 gpm
[7] LEGEND: 6 Hydraulic System Manifold 7 Right Side Hydraulic Fan Speed Solenoid
Right Side Fan Motor Speed Solenoid Right Side Hydraulic Fan— Disconnect the right side hydraulic fan speed solenoid (7) located on the hydraulic system manifold (6). [8] - Operate engine at slow idle. Record flow and compare to specification. Item
Measurement
Specification
Slow Idle
Speed
900 rpm
Right Fan Hydraulic Pump
Flow Rate
25 L/min 6 gpm
[9] - Operate engine at high idle. Record flow and compare to specification. Item
Measurement
Specification
High Idle
Speed
2270 rpm
Right Fan Hydraulic Pump
Flow Rate
203 L/min 14 gpm
[10] - If flow to the hydraulic motor is to specification replace the hydraulic fan motor. If flow to the hydraulic motor is not to specification check the following:
<- Go to Section TOC
Section 9025 page 94
TM12406-OPERATION AND TEST MANUAL
HEATING AND AIR CONDITIONING
(g) by Belgreen v2.0
a. Right Fan—Repair or replace the hydraulic fan pump. See Left Hydraulic Fan Pump Remove and Install . b. Left Fan—Check the main hydraulic pump margin and maximum pressure. See Main Hydraulic Pump Margin and Maximum Pressure Test and Adjustment . (Group 9025-25.)
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Section 9031 page 95
TM12406-OPERATION AND TEST MANUAL
TM12406-OPERATION AND TEST MANUAL
(g) by Belgreen v2.5
Section 9031 - HEATING AND AIR CONDITIONING Table of contents Group 05 - Theory of Operation ............................................................................................................. 1 Air Conditioning System Cycle of Operation ......................................................................................... 1 Heater Core Operation ......................................................................................................................... 2 Group 15 - Diagnostic Information ........................................................................................................ 3 Air Conditioner and Heater Component Location ................................................................................. 3 Air Conditioning System Does Not Operate Diagnostic Procedure ....................................................... 7 Air Conditioner Does Not Cool Interior of Cab Diagnostic Procedure .................................................... 9 Air Conditioner Runs Constantly, Too Cold Diagnostic Procedure ....................................................... 11 Interior Windows Continue to Fog Diagnostic Procedure .................................................................... 11 Heater System Does Not Operate Diagnostic Procedure .................................................................... 13 Heater Does Not Warm Interior of Cab Diagnostic Procedure ............................................................ 14 Group 25 - Tests ..................................................................................................................................... 16 Refrigerant Cautions and Proper Handling ......................................................................................... 16 Air Conditioner and Heater Operational Checks ................................................................................. 17 R134a Air Conditioning System Test .................................................................................................. 19 Operating Pressure Diagnostic Chart .................................................................................................. 21 Air Conditioner Freeze Control Switch Test ........................................................................................ 22 Air Conditioner Compressor Clutch Test ............................................................................................. 22 Air Conditioner High/Low-Pressure Switch Test .................................................................................. 24 Air Conditioner Expansion Valve Test ................................................................................................. 26 Blower Motor Resistor/Thermofuse Test ............................................................................................. 28 Blower Motor Test ............................................................................................................................... 28 Expansion Valve Bench Test ............................................................................................................... 30 Refrigerant Leak Test ......................................................................................................................... 31
<- Go to Global Table of contents
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 05: Theory of Operation
Group 05 - Theory of Operation Air Conditioning System Cycle of Operation
Refrigerant System Cycle of Operation LEGEND: 1 2 3 4 5 6 7 8 9 10 11
Evaporator Core Compressor Condenser Core Circulation Blower Motor Expansion Valve Receiver-Dryer High Pressure Liquid High Pressure Gas Low Pressure Liquid Low Pressure Gas Air Flow
The compressor is belt driven and engaged by an electromagnetic clutch. The compressor draws low pressure gas from the evaporator and compresses it into high pressure gas. This causes the temperature of the refrigerant to rise higher than that of outside air. High pressure gas leaves the compressor and flows through the condenser, where heat is removed and transferred to outside air being drawn through the condenser core by the engine fan. Cooling the refrigerant causes it to condense, and the refrigerant leaves the condenser as high pressure liquid. High pressure liquid flows into the receiver-dryer, where moisture and contaminants (acid, solids, etc.) are removed. The receiver-dryer contains a color moisture indicator. Blue indicates no moisture is present. Pink indicates moisture is present. 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. The receiver-dryer also stores refrigerant, allowing a longer period of <- Go to Section TOC
Section 9031 page 1
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 15: Diagnostic Information
time before additional refrigerant is needed. Refrigerant hoses allow a small amount of refrigerant to migrate through their walls. Refrigerant flows from the receiver-dryer through the expansion valve to the evaporator. The expansion valve senses refrigerant temperature and pressure to modulate refrigerant flow. The expansion valve changes the refrigerant to low pressure liquid entering the evaporator. Actual cooling and drying of cab air takes place at the evaporator. Heat absorbed by the evaporator and transferred to the refrigerant causes the refrigerant to vaporize into low pressure gas. Low pressure gas is drawn from the evaporator by the compressor and the cycle is repeated. A freeze control switch senses the temperature of the evaporator coil through a capillary tube. This prevents the evaporator from becoming cold enough to freeze the moisture that condenses on the evaporator coil. Condensed moisture is drained away through drain tubes connected to the drain pan under the evaporator. System pressure is monitored by the high/low pressure switch, located on the high pressure side of expansion valve. If pressure becomes too high or too low, the switch opens and stops the compressor, interrupting the cycle. The accumulator (if equipped) is located between the evaporator and compressor in the low pressure gas hose to retain a quantity of oil to protect the compressor from a dry start after long periods of not being used. For the location of the machine heater and air conditioning components, See Air Conditioner and Heater Component Location . (Group 9031-15.)
Heater Core Operation The heater core is located near the evaporator in the heating and air conditioning module on the right side of the cab. Filtered air flows through the evaporator, removing moisture before flowing though the heater core. The heater core uses warm engine coolant to heat a mixture of inside cab air as well as outside air pulled across the heater core. Coolant flow through the heater core is regulated by the heater valve. The heater valve is regulated by an actuator, which is controlled by the heater valve control module in response to the position of the temperature control switch. See Air Conditioner and Heater Component Location . (Group 9031-15.)
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Section 9031 page 2
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 15: Diagnostic Information
Group 15 - Diagnostic Information Air Conditioner and Heater Component Location
Heater/Air Conditioner Component Location LEGEND: 1 2 <- Go to Section TOC
Condenser Compressor Section 9031 page 3
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
3 4 5 6 7 8 9 10 11
Group 15: Diagnostic Information
Heater Return Line Heater Supply Line Receiver-Dryer Air Conditioner High/Low Pressure Switch Low-Pressure Charging Port Expansion Valve Heater Control Valve Heater Core Evaporator Core
Air Conditioner Component Location (S.N. —664056) LEGEND: 8 9 10 11 12 13 14 15 16 17
<- Go to Section TOC
Expansion Valve Heater Control Valve Heater Core Evaporator Core Air Intake Filter Recirculating Damper Blower Motor and Housing Floor Vent Actuator Defrost Actuator Freeze Control Switch
Section 9031 page 4
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Section 9031 - HEATING AND AIR CONDITIONING
Group 15: Diagnostic Information
Air Conditioner Component Location (S.N. 664057—667261) LEGEND: 8 9 10 11 12 13 14 15 16 17
<- Go to Section TOC
Expansion Valve Heater Control Valve Heater Core Evaporator Core Air Intake Filter Recirculating Damper Blower Motor and Housing Floor Vent Actuator Defrost Actuator Freeze Control Switch
Section 9031 page 5
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 15: Diagnostic Information
Air Conditioner Component Location (S.N. 667262— ) LEGEND: 8 9 10 11 12 13 14 15 16 17
<- Go to Section TOC
Expansion Valve Heater Control Valve Heater Core Evaporator Core Air Intake Filter Recirculating Damper Blower Motor and Housing Floor Vent Actuator Defrost Actuator Freeze Control Switch
Section 9031 page 6
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 15: Diagnostic Information
Air Conditioning System Does Not Operate 70
Air Conditioning System Does Not Operate Diagnostic Procedure ( 1 ) Code Check
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Diagnose code. See specific code diagnostic procedure in Group 9001. NO:Go to Blower Speed Check. ( 2 ) Blower Speed Check
Action: Push blower speed button on 15-button sealed switch module (SSM) (OC4) three times. Do LEDs on blower switch light up and does blower speed go from slow, medium, to high?
Result: YES: Go to Air Conditioner Compressor Clutch Check . NO:Go to Blower Motor Resistor Check. ( 3 ) Blower Motor Resistor Check
Action: Check blower motor resistor/thermofuse. See Blower Motor Resistor/Thermofuse Test . (Group 9031-25.) Does resistor/thermofuse test OK?
Result: YES:Replace blower motor. NO:Replace blower motor resistor/thermofuse. ( 4 ) Air Conditioner Compressor Clutch Check
Action: Check air conditioner compressor clutch. See Air Conditioner Compressor Clutch Test . (Group 9031-25.) Does compressor clutch test OK?
Result: YES:Go to Freeze Control Switch Check. NO:Replace air conditioner compressor. See Compressor Remove and Install . (Group 1830.) ( 5 ) Freeze Control Switch Check
Action: Check freeze control switch. See Air Conditioner Freeze Control Switch Test . (Group 9031-25.) Does freeze control switch test OK?
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Section 9031 page 7
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 15: Diagnostic Information
Result: YES:Go to High/Low-Pressure Switch Check. NO:Replace freeze control switch. See Freeze Control Switch Remove and Install . (Group 1830.) ( 6 ) High/Low-Pressure Switch Check
Action: Check high/low-pressure switch. See Air Conditioner High/Low-Pressure Switch Test . (Group 9031-25.) Does pressure switch test OK?
Result: YES:Go to Air Conditioning System Check. NO:Replace pressure switch. See High/Low-Pressure Switch Remove and Install . (Group 1830.) ( 7 ) Air Conditioning System Check
Action: Ignition ON. Does air conditioning system works efficiently?
Result: YES:Checks complete. NO:Replace the evaporator. See Air Conditioner and Heater Component Location . (Group 9031-15.)
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Section 9031 page 8
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 15: Diagnostic Information
Air Conditioner Does Not Cool Interior of Cab 70
Air Conditioner Does Not Cool Interior of Cab Diagnostic Procedure ( 1 ) Code Check
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Diagnose code. See specific code diagnostic procedure in Group 9001. NO:Go to Blend Air and Mode Doors Check. ( 2 ) Blend Air and Mode Doors Check
Action: Check blend air and mode doors for physical obstructions, smooth operation, and proper positioning on the primary display unit (PDU). See Diagnostics—ATC Readings . (Group 9015-16.) Are the doors free of obstructions, in the proper position and operating smoothly?
Result: YES:Go to Air Filter Check. NO:Replace mode doors. See Mode Door Remove and Install . (Group 1830.) ( 3 ) Air Filter Check
Action: Check air filter for clogging or restrictions. Is air filter clogged or restricted?
Result: YES:Replace air filter. NO:Go to Condenser and Evaporator Restriction Check. ( 4 ) Condenser and Evaporator Restriction Check
Action: Check condenser and evaporator fins for air flow restrictions. Are condenser or evaporator fins clogged with debris?
Result: YES:Clean condenser and evaporator fins. NO:Go to Hose Check. ( 5 ) Hose Check
Action: Check for kinked, pinched or collapsed heater/air conditioner hoses. See Air Conditioner and Heater Component Location . (Group 9031-15.) Are any hoses kinked, pinched, or collapsed? <- Go to Section TOC
Section 9031 page 9
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 15: Diagnostic Information
Result: YES:Replace or re-route hoses. NO:Go to Blower Speed Check. ( 6 ) Blower Speed Check
Action: Push blower speed button on 15-button sealed switch module (SSM) (OC4) three times. Do LEDs on blower switch light up and does blower speed go from slow, medium, to high?
Result: YES: Go to Heater Valve Check . NO:Go to Blower Motor Resistor Check. ( 7 ) Blower Motor Resistor Check
Action: Check blower motor resistor/thermofuse. See Blower Motor Resistor/Thermofuse Test . (Group 9031-25.) Does resistor/thermofuse test OK?
Result: YES: See Blower Motor Assembly Remove and Install . (Group 1830.) NO:Replace blower motor resistor/thermofuse. ( 8 ) Heater Valve Check
Action: Check heater valve and cable for proper operation. Is heater valve stuck open?
Result: YES:Replace heater valve and cable. NO:Go to Freeze Control Switch Check. ( 9 ) Freeze Control Switch Check
Action: Check freeze control switch. See Air Conditioner Freeze Control Switch Test . (Group 9031-25.) Does freeze control switch test OK?
Result: YES: Perform R134a Air Conditioning System Test . (Group 9031-25.) NO:Replace freeze control switch. See Freeze Control Switch Remove and Install . (Group 1830.)
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Section 9031 - HEATING AND AIR CONDITIONING
Group 15: Diagnostic Information
Air Conditioner Runs Constantly, Too Cold 70
Air Conditioner Runs Constantly, Too Cold Diagnostic Procedure ( 1 ) Code Check
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Diagnose code. See specific code diagnostic procedure in Group 9001. NO:Go to Blend Air and Mode Doors Check ( 2 ) Blend Air and Mode Doors Check
Action: Check blend air and mode doors for physical obstructions, smooth operation, and proper positioning on the primary display unit (PDU). See Diagnostics—ATC Readings . (Group 9015-16.) Are the doors free of obstructions, in the proper position and operating smoothly?
Result: YES:Go to Evaporator Core Fins Check. NO:Replace mode doors. See Mode Door Remove and Install . (Group 1830.) ( 3 ) Evaporator Core Fins Check
Action: Check evaporator core fins for frosting or freezing. See Air Conditioner and Heater Component Location . (Group 9031-15.) Is ice or frost present on evaporator fins?
Result: YES:Reposition freeze control switch in evaporator. NO:Go to Freeze Control Switch Check. ( 4 ) Freeze Control Switch Check
Action: Check freeze control switch. See Air Conditioner Freeze Control Switch Test . (Group 9031-25.) Does freeze control switch test OK?
Result: YES:Checks complete. NO:Replace freeze control switch. See Freeze Control Switch Remove and Install . (Group 1830.) Interior Windows Continue to Fog 70
Interior Windows Continue to Fog Diagnostic Procedure ( 1 ) Fresh Air Filter Check
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Section 9031 page 11
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Section 9031 - HEATING AND AIR CONDITIONING
Group 15: Diagnostic Information
Action: Check fresh air filter for clogging and restrictions. Is fresh air filter clogged or restricted?
Result: YES:Clean or replace fresh air filter. NO:Go to Air Conditioning ON/OFF Check. ( 2 ) Air Conditioning ON/OFF Check
Action: Is air conditioning ON?
Result: YES: See Air Conditioning System Does Not Operate . (Group 9031-15.) NO:Push air conditioning button on 15-button sealed switch module (SSM) (OC4).
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Section 9031 page 12
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 15: Diagnostic Information
Heater System Does Not Operate 70
Heater System Does Not Operate Diagnostic Procedure ( 1 ) Code Check
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Diagnose code. See specific code diagnostic procedure in Group 9001. NO:Go to Blower Speed Check. ( 2 ) Blower Speed Check
Action: Push blower speed button on 15-button sealed switch module (SSM) (OC4) three times. Do LEDs on blower switch light up and does blower speed go from slow, medium, to high?
Result: YES:Checks complete. NO:Go to Blend Air and Mode Doors Check ( 3 ) Blend Air and Mode Doors Check
Action: Check blend air and mode doors for physical obstructions, smooth operation, and proper positioning on the primary display unit (PDU). See Diagnostics—ATC Readings . (Group 9015-16.) Are the doors free of obstructions, in the proper position and operating smoothly?
Result: YES:Go to Blower Motor Resistor Check. NO:Replace mode doors. See Mode Door Remove and Install . (Group 1830.) ( 4 ) Blower Motor Resistor Check
Action: Check blower motor resistor/thermofuse. See Blower Motor Resistor/Thermofuse Test . (Group 9031-25.) Does resistor/thermofuse test OK?
Result: YES: Perform Blower Motor Test . (Group 9031-25.) NO:Replace blower motor resistor/thermofuse.
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Section 9031 page 13
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Section 9031 - HEATING AND AIR CONDITIONING
Group 15: Diagnostic Information
Heater Does Not Warm Interior of Cab 70
Heater Does Not Warm Interior of Cab Diagnostic Procedure ( 1 ) Code Check
Action: Check for active diagnostic trouble codes (DTCs). See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application . (Group 9015-20.) Are any DTCs present?
Result: YES:Diagnose code. See specific code diagnostic procedure in Group 9001. NO:Go to Coolant Temperature Check. ( 2 ) Coolant Temperature Check
Action: Check engine coolant temperature on the CAN monitor unit (CMU). See CAN Monitor Unit (CMU)—ECU Readings . (Group 9015-16.) Is coolant temperature to operating temperature?
Result: YES:Go to Blend Air and Mode Doors Check. NO:Warm engine coolant to operating temperature. ( 3 ) Blend Air and Mode Doors Check
Action: Check blend air and mode doors for physical obstructions, smooth operation, and proper positioning on the primary display unit (PDU). See Diagnostics—ATC Readings . (Group 9015-16.) Are the doors free of obstructions, in the proper position, and operating smoothly?
Result: YES:Go to Air Filter Check. NO:Replace mode doors. See Mode Door Remove and Install . (Group 1830.) ( 4 ) Air Filter Check
Action: Check air filter for air flow restrictions. Is air filter clogged or restricted?
Result: YES:Replace air filter. NO:Go to Heater Core Check. ( 5 ) Heater Core Check
Action: Check heater core for air flow restrictions. See Air Conditioner and Heater Component Location . (Group 9031-15.) Are heater core fins clogged with debris? <- Go to Section TOC
Section 9031 page 14
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Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
Result: YES:Clean heater core fins. NO:Go to Hose Check. ( 6 ) Hose Check
Action: Check for kinked, pinched, or collapsed heater/air conditioner hoses. See Air Conditioner and Heater Component Location . (Group 9031-15.) Are any hoses kinked, pinched, or collapsed?
Result: YES:Replace or reroute hoses. NO:Go to Blower Speed Check. ( 7 ) Blower Speed Check
Action: Push blower speed button on 15-button sealed switch module (SSM) (OC4) three times. Do LEDs on blower switch light up and does blower speed go from slow, medium, to high?
Result: YES: Go to Heater Valve Check . NO:Go to Blower Motor Resistor Check. ( 8 ) Blower Motor Resistor Check
Action: Check blower motor resistor/thermofuse. See Blower Motor Resistor/Thermofuse Test . (Group 9031-25.) Does resistor/thermofuse test OK?
Result: YES: Perform Blower Motor Test . (Group 9031-25.) NO:Replace blower motor resistor/thermofuse. ( 9 ) Heater Valve Check
Action: Check heater valve and cable for proper operation. Is heater valve stuck closed or cable broken?
Result: YES:Replace heater valve and cable. NO:Checks complete.
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Section 9031 page 15
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
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. JDG10933 Refrigerant Identifier should be used before any testing or repair to system is preformed. Refrigerant Identifier JDG10933 To safely identify type and check purity of refrigerant prior to recovery, recycling, and recharging of A/C systems.
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Section 9031 page 16
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Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
Air Conditioner and Heater Operational Checks Visual Inspection of Components →NOTE: Do a visual inspection of components prior to diagnosis and component tests. These conditions may affect diagnostic and test results. All Lines and Hoses [1] - Inspect all lines and hoses. See Air Conditioner and Heater Component Location . (Group 9031-15.) [2] - Inspect lines and hoses for wear from rubbing on one another or other machine parts. Make sure that lines and hoses are not kinked. Check rubber hoses for weather checking. [3] - Are hose and line connections clean? Inspect for signs of leakage, such as oil or dust accumulation at fittings. [4] - All hose and line clamps must be in place and tight. Clamps must have rubber inserts or cushions in place to prevent clamps from crushing or wearing into hoses or lines. Yes: Check complete. No: Reposition hoses or lines and tighten or replace clamps. Tighten fittings or replace O-rings in fittings. Replace hoses or lines as required. Air Conditioner Compressor Check [1] - Inspect compressor. [2] - Is compressor drive belt tight? [3] - Is belt in good condition? Inspect for frayed, worn, or glazed belt. [4] - Is belt tensioner in good condition? Is tensioner worn or damaged? [5] - Is compressor belt pulley in good condition and in line with engine pulley? [6] - Are compressor mounting brackets in good condition? Are bracket mounting cap screws tight? [7] - Are electrical connections to compressor clutch clean and tight? Is wiring to compressor in good condition? Yes: Check complete. No: Repair or replace components as required. Condenser Check [1] - Inspect condenser core. [2] - Is condenser core free of dirt and debris? [3] - Is condenser in good condition? Inspect for signs of leakage, dust accumulation, or oily areas. [4] - Are condenser fins straight? [5] - Inspect condenser fan or fan blade. [6] - Are fan blades in good condition? Inspect for worn, bent, broken, or missing fan blades. Yes: Check complete. No: Clean, repair, or replace condenser core. Replace condenser fan or fan blade. Heater/Evaporator Core Check [1] - Inspect core. [2] - Are fins straight? [3] - Is core free of dirt and debris? <- Go to Section TOC
Section 9031 page 17
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Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
[4] - Are evaporator drain tubes free of obstructions? Yes: Check complete. No: Repair, replace, or clean heater/evaporator core and drain tubes. See Heater Core and Evaporator Core Remove and Install . (Group 1830.) Freeze Control Switch Capillary Tube Check [1] - Inspect freeze control switch capillary tube. [2] - Is capillary tube kinked or broken? [3] - Is capillary tube properly positioned and inserted securely in place in evaporator core? Yes: Check complete. No: If capillary tube is kinked, replace freeze control switch. No: If capillary tube is positioned in evaporator incorrectly, perform Air Conditioner Freeze Control Switch Test . Cab Door and Window Seals Check [1] - Open and close door and windows. Inspect seals. [2] - Do door and windows contact seals evenly? [3] - Are seals in position and in good condition? Yes: Check complete. No: Adjust door and windows to close against seals properly. Replace seals as necessary. Filter Check [1] - Inspect air filter. [2] - Is air filter clean and free of debris? Yes: Check complete. No: Clean or replace filter.
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Section 9031 page 18
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
R134a Air Conditioning System Test [1] IMPORTANT: Use correct refrigerant recovery, recycling, and charging stations. DO NOT mix refrigerant, hoses, fitting, components, or refrigerant oils. Stop the engine. [2] - Follow refrigerant cautions and proper handling procedures. See Refrigerant Cautions and Proper Handling . (Group 9031-25.) [3] - Identify refrigerant type using JT02167A Prism Pro Refrigerant Identification Instrument. Prism Pro Refrigerant Identification Instrument JT02167A Identify type of refrigerant used in air conditioning system prior to recovery, recycling, and charging. →NOTE: Follow manufacturer′s instructions when operating refrigerant recovery, recycling, and charging station. [4] - Connect refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure . (Group 1830.) [5] - Open both low and high pressure valves on refrigerant recovery, recycling, and charging station. [6] - Start engine and run at specification. Item
Measurement
Specification
Engine
Speed
2420 rpm
[7] - Press the air conditioning/heater switch on the 15-button sealed switch module (SSM) (OC4) to the ON position. [8] - Press the temperature button on the 15-button SSM (OC4) to maximum cooling. [9] - Push blower switch 15-button SSM (OC4) until all 3 LEDs are on. [10] - Open cab doors and windows. [11] - Run system for at least five minutes. [12] - Measure and record air temperatures at cab air filter inlet and at air ducts in cab. Compare to specifications. Air Conditioner Air Inlet and Outlet Temperatures Temperature Range
Maximum Expected Air Temperature at Ducts in Cab
21.1—26.7°C 70—80°F
7.3—7.7°C 45—46°F
26.7—32.2°C 80—90°F
7.5—10.6°C 45—51°F
32.2—37.8°C 90—100°F
10.6—14.9°C 51—59°F
37.8—43.3°C 100—110°F
14.9—20.2°C 58—68°F
[13] - Observe suction pressure and discharge pressure on gauges. Compare to specifications. Suction and Discharge Pressure Readings Ambient Air Temperature
Suction Pressure
Discharge Pressure
21.1—26.7°C 70—80°F
91—97 kPa 0.91—0.97 bar 13—14 psi
864—1012 kPa 8.64—10.12 bar 125—147 psi
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Section 9031 page 19
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
26.7—32.2°C 80—90°F
97—128 kPa 0.97—1.28 bar 14—18 psi
1012—1228 kPa 10.12—12.28 bar 147—178 psi
32.2—37.8°C 90—100°F
128—164 kPa 1.28—1.64 bar 18—24 psi
1228—1482 kPa 12.28—14.82 bar 178—215 psi
37.8—43.3°C 100—110°F
164—210 kPa 1.64—2.10 bar 24—30 psi
1482—1795 kPa 14.82—17.95 bar 215—260 psi
[14] - If measurements do not meet specifications, diagnose malfunction. See Operating Pressure Diagnostic Chart . (Group 9031-25.)
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Section 9031 page 20
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
Operating Pressure Diagnostic Chart Perform the following procedures in Group 1830 to service air conditioning system: Perform R134a Refrigerant Recover . (Group 1830.) Perform R134a System Evacuate . (Group 1830.) See R134a System Charge . (Group 1830.) Pressure Diagnostic Chart
Condition
Low Side kPa bar psi
High Side kPa bar psi
Sight Glass
Suction Line
Receiver-Dryer
Liquid Line
Discharge Line
Discharge Air
Lack of Refrigerant
Very Low
Very Low
Clear
Slightly Cool
Slightly Warm
Slightly Warm
Slightly Warm
Warm
Loss of Refrigerant
Low
Low
Bubbles
Cool
Warm to Hot
Warm
Warm to Hot
Slightly Cool
High Side Restriction
Low
Low
Clear
Cool
Cool, Sweating or Frosting
Cool, Sweating or Frosting
Hot to Point of Restriction
Slightly Cool
Warm
Warm
Hot
Slightly Cool
Expansion Valve Closed
Low
Low
Clear
Cold, Sweating or Frosting Heavily at Valve Outlet
Loose Belt or Compressor Failure
High
Low
Clear
Cool
Warm
Warm
Warm
Slightly Cool
Condenser Malfunction
High
High
Clear to Occasional Bubbles
Slightly Cool to Warm
Hot
Hot
Hot
Warm
Refrigerant Contaminated and Air in System
High
High
Bubbles
Warm to Hot
Warm
Warm
Hot
Warm
Expansion Valve Open
High
High
Clear
Cold, Sweating or Frosting Heavily
Warm
Warm
Hot
Slightly Cool
Plugged Condenser, Overcharge of Refrigerant
Normal
High
Clear
Cool
Warm
Warm
Hot
Slightly Cool
Moisture in System
Normal (May Drop)
Normal (May Drop)
Clear
Cool
Warm
Warm
Hot
Cool to Warm
Heater Valve Stuck Open
Normal
Normal
Clear
Cool
Warm
Warm
Hot
Warm
Lack of Refrigerant and Air in System
Normal (No Drop)
Normal
Occasional Bubbles
Warm to Hot
Warm
Warm
Warm
Slightly Cool
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Section 9031 page 21
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Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
Air Conditioner Freeze Control Switch Test
Air Conditioner Freeze Control Switch Specifications SPECIFICATIONS Freeze Control Switch Opens (Normally Closed)—Temperature Drops (S.N. —664056)
1—3°C 33.8—37.4°F
Freeze Control Switch Opens (Normally Closed)—Temperature Drops (S.N. 664057— )
0.5—1.7°C 33—35°F
Freeze Control Switch Closes (Normally Closed)—Temperature Rises (S.N. —664056)
1—3°C 33.8—37.4°F
Freeze Control Switch Closes (Normally Closed)—Temperature Rises (S.N. 664057— )
3.3—4.4°C 38—40°F
[1] - Mark position of capillary tube. Tube should be near center of evaporator. [2] - Disconnect and remove freeze control switch. [3] - With freeze control switch at room temperature, connect terminals to ohmmeter and measure continuity between terminals. [4] - Is continuity measured? Yes: Switch is good. Check wiring harness. No: Replace freeze control switch. [5] - Put freeze control switch in freezer. Temperature must be below 1—3°C (33.8—37.4°F) for (S.N. —664056) and 0.5—1.7°C (33—35°F) for (S.N. 664057— ). Switch must be open and continuity must not be read. [6] - Remove switch from freezer and put sensing tube into a glass of warm water. As switch warms it must close and continuity must be read. Item
Measurement
Specification
Freeze Control Switch Opens (Normally Closed)—Temperature Drops
Temperature (S.N. —664056)
1—3°C
Freeze Control Switch Opens (Normally Closed)—Temperature Drops
Temperature (S.N. 664057— )
33.8—37.4°F 0.5—1.7°C 33—35°F Freeze Control Switch Closes (Normally Closed)—Temperature Rises
Temperature (S.N. —664056)
1—3°C 33.8—37.4°F
Freeze Control Switch Closes (Normally Closed)—Temperature Rises
Temperature (S.N. 664057— )
3.3—4.4°C 38—40°F
Air Conditioner Compressor Clutch Test
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Section 9031 page 22
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
Air Conditioner Compressor Clutch [1] - Disconnect harness from clutch. [2] - Connect battery voltage to connector terminal for orange wire. Ground terminal for black wire. [3] - Does clutch “click”? Yes: Clutch coil is good. Check wiring harness. No: Replace clutch coil.
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Section 9031 page 23
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
Air Conditioner High/Low-Pressure Switch Test Specifications SPECIFICATIONS Air Conditioner Low-Pressure Switch (normally open)—Closes on Increasing Pressure
177—237 kPa 1.77—2.37 bar 26—35 psi
Air Conditioner Low-Pressure Switch (normally open)—Opens on Decreasing Pressure
180—220 kPa 1.8—2.2 bar 26—32 psi
Air Conditioner High-Pressure Switch (normally closed)—Opens on Increasing Pressure
2500—2900 kPa 25—29 bar 363—421 psi
Air Conditioner High-Pressure Switch (normally closed)—Closes on Decreasing Pressure
1900—2300 kPa 19—23 bar 276—334 psi
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Hydraulic Hand Pump Volt-Ohm-Amp Meter Air Conditioning Gauge Set
→NOTE: The line that attaches air conditioner high/low-pressure switch has a valve under it to prevent discharging air conditioning system when switch is removed. LEGEND: 1 Wire Connectors 2 High/Low-Pressure Switch
High/Low-Pressure Switch [1] - Remove air conditioner high/low-pressure switch (2). [2] - Connect air conditioner high/low-pressure switch to a pressure source such as a regulated air supply or dry nitrogen. Hydraulic Hand Pump To provide pressure. [3] - Connect a volt-ohm-amp meter to the switch terminals. Switch must not have continuity between terminals until pressure increases to low-pressure switch specification. Slowly release pressure. Switch must have continuity until pressure decreases to switch opening pressure specification. Volt-Ohm-Amp Meter To measure continuity. <- Go to Section TOC
Section 9031 page 24
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
Item
Measurement
Specification
Air Conditioner Low-Pressure Switch (Normally Open)—Closes on Increasing
Pressure
177—237 kPa 1.77—2.37 bar 26—35 psi
Air Conditioner Low-Pressure Switch (Normally Open)—Opens on Decreasing
Pressure
180—220 kPa 1.8—2.2 bar 26—32 psi
[4] - Switch must have continuity between terminals until pressure increases to high-pressure opening specification. Item
Measurement Specification
Air Conditioner High-Pressure Switch (Normally Closed)—Opens on Increasing
Pressure
2500—2900 kPa 25—29 bar 363—421 psi
[5] - Slowly release pressure. Switch must not have continuity until pressure decreases to switch closing pressure specification. Item
Measurement Specification
Air Conditioner High-Pressure Switch (Normally Closed)—Closes on Decreasing
Pressure
1900—2300 kPa 19—23 bar 276—334 psi
→NOTE: The switch can also be checked when installed in air conditioning system; however, pressure is slow to increase to test specification. [6] - 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 A/C high-pressure switch opens and then closes. Air Conditioning Gauge Set To measure high-side pressure when A/C high-pressure switch opens and then closes.
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Section 9031 page 25
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
Air Conditioner Expansion Valve Test LEGEND: 1
Sensing Bulb
Sensing Bulb Specifications SPECIFICATIONS Engine Speed
Fast Idle 2220—2260 rpm
Blower Speed
High
Temperature Control Switch Position
Maximum Cooling
Essential Tools ESSENTIAL TOOLS Refrigerant Recovery, Recycling, and Charging System
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Thermometer
IMPORTANT: Use correct refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components, or refrigerant oils. [1] - Follow refrigerant cautions and proper handling procedures. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) [2] - Connect refrigerant recovery, recycling and charging system. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure . (Group 1830.) [3] - Perform R134a Refrigerant Recover . (Group 1830.) Refrigerant Recovery, Recycling and Charging System To recover and recycle refrigerant, and to charge the air conditioning system. Thermometer To measure temperature. [4] - Remove insulating tape from expansion valve sensing bulb. [5] - Remove sensing bulb (1). [6] - Start engine and run at fast idle. Item
Measurement
Specification
Engine
Speed
Fast Idle 2220—2260 rpm
[7] - Press blower control on 15-button sealed switch module (SSM) (OC4) until all 3 LEDs are on, then press temperature control on 15-button SSM (OC4) to maximum cooling. <- Go to Section TOC
Section 9031 page 26
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
Item
Measurement
Specification
Blower
Speed
High
Temperature Control Switch
Position
Maximum Cooling
[8] - Warm sensing bulb in the hand for one minute. Note low-side pressure. [9] - Cool sensing bulb in ice water. Note low-side pressure. If low-side pressure decreases when sensing bulb is cooled, expansion valve is operating. If low-side pressure does not decrease, perform Expansion Valve Bench Test . (Group 9031-25.) [10] - Before fastening sensing bulb to evaporator outlet line, make sure line and bulb are not corroded. Fasten sensing bulb to side of line with clamp. Install insulating tape to completely cover sensing bulb and line.
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Section 9031 page 27
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
Blower Motor Resistor/Thermofuse Test Blower Motor Resistor/Thermofuse R11 Specifications BLOWER MOTOR RESISTOR/THERMOFUSE R11 SPECIFICATIONS Blower Motor Resistor Resistance (between terminals 2 and 6)
0.1—0.5 ohm
Blower Motor Resistor Resistance (between terminals 5 and 6)
1.0—1.4 ohms
Blower Motor Resistor Resistance (between terminals 3 and 6)
4.1—5.3 ohms
[1] - Turn battery disconnect switch to the OFF position. [2] - Disconnect wires from blower motor resistors/thermofuses R11. See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.) [3] -
Blower Motor Resistor/Thermofuse LEGEND: 1 Blower Motor Reistor/Thermofuse R11 2 Terminal 1 3 Terminal 2 4 Thermofuse 5 Terminal 3 6 Terminal 4 Using a multimeter, measure resistance between the following terminals: terminal 2 and terminal 6 (thermofuse) terminal 5 and terminal 6 terminal 3 and terminal 6 Compare resistance to specification. Item
Measurement
Specification
Blower Motor Resistor
Resistance (between terminals 2 and 6)
0.1—0.5 ohm
Resistance (between terminals 5 and 6)
1.0—1.4 ohms
Resistance (between terminals 3 and 6)
4.1—5.3 ohms
If resistance is not to specification, replace blower motor resistor.
Blower Motor Test [1] - Turn battery disconnect OFF. [2] - Disconnect blower motor. See Air Conditioner Unit Harness (W16) Component Location . (Group 9015-10.)
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Section 9031 page 28
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
[3] - Apply 12 volts to terminal A and ground to terminal B on blower motor. If blower motor operates, motor is OK. If blower motor does not operate, replace blower motor.
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Section 9031 page 29
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
Expansion Valve Bench Test LEGEND: 1 JT03184 Tee Fitting with 0.020 inch Orifice Cap 2 JT03183 Fitting 3 JT03195 Tee Fitting
Test Fittings Specifications SPECIFICATIONS High-Side Valve Pressure Setting
520 kPa 5.2 bar 75 psi
Expansion Valve—Opens on Increasing Pressure
280—380 kPa 2.8—3.8 bar 40—55 psi
Expansion Valve—Closes on Decreasing Pressure
140—170 kPa 1.4—1.7 bar 20—25 psi
Essential Tools ESSENTIAL TOOLS JT05419 Air Conditioning Service Fitting Kit
Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS Air Conditioning Gauge Set
[1] - Follow refrigerant cautions and proper handling procedures. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) [2] - Remove expansion valve. See Expansion Valve Remove and Install . (Group 1830.) [3] - Connect A/C expansion valve to air conditioning gauge set using fittings (1—3). Air Conditioning Service Fitting Kit JT05419 To connect the A/C expansion valve to air conditioning gauge set. Air Conditioning Gauge Set <- Go to Section TOC
Section 9031 page 30
TM12406-OPERATION AND TEST MANUAL
Section 9031 - HEATING AND AIR CONDITIONING
Group 25: Tests
To measure pressure. [4] - Connect yellow hose to a regulated air supply. [5] - Close low-side valve and open high-side valve. [6] - Adjust pressure on high-side valve to 520 kPa (5.2 bar) (75 psi) using a pressure regulator or by adjusting high-side valve. Item
Measurement
Specification
High-Side Valve Pressure Setting
Pressure
520 kPa 5.2 bar 75 psi
[7] - Hold sensing bulb in hand until pressure on low-side gauge stops increasing. Pressure must be 280—380 kPa (2.8—3.8 bar) (40—55 psi). Item
Measurement
Specification
Expansion Valve—Opens on Increasing
Pressure
280—380 kPa 2.8—3.8 bar 40—55 psi
[8] - Put sensing bulb in a container of ice water until pressure on low-side gauge stops decreasing. Pressure must be 140—170 kPa (1.4—1.7 bar) (20—25 psi). Item
Measurement
Specification
Expansion Valve—Closes on Decreasing
Pressure
140—170 kPa 1.4—1.7 bar 20—25 psi
Refrigerant Leak Test Specifications SPECIFICATIONS Leak Detector Probe Movement Speed
25 mm (1 inch) per second
CAUTION: The refrigerant is under high pressure and the system must be serviced by qualified personnel only. Improper service methods may cause injury. If accidental system discharge occurs, ventilate the work area before resuming work. Avoid breathing in the air conditioner refrigerant and lubricant vapor or mist. Exposure may irritate the eyes, nose, and throat. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. [1] - Inspect all lines, fittings, and components for oily or dusty spots. When refrigerant leaks from system, a small amount of oil is carried out with it. [2] - A soap and water solution can be sprayed on the components in system to form bubbles at source of leak. [3] - If a leak detector is used, move leak detector probe under hoses and around connections at a rate of 25 mm (1 inch) per second. Item
Measurement
Specification
Leak Detector Probe Movement
Speed
25 mm (1 inch) per second
→NOTE: Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.
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TM12406-OPERATION AND TEST MANUAL